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SERVICE MANUAL L40-L100 AIR COOLED LA SERIES

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1. Cylinder head gt Tighten gt Check tightening improperly tightened evenly torque Broken cylinder head gasket Replace gasket Occurs when the cylinder head is not tightened evenly 97 MA Final steps Poor quality Troubleshooting lubricating ol Deteriorated Lubricating oil viscosity too low Change oil Change oil every 100 hrs For API Class CC and CD warm weather SAE 30 in cold weather 10W30 Piston ring sticking gt Wash or replace gt Notes for the ring replacing a Remove carbon deposited in piston fing grooves b The manufacturers mark on the piston ring end should face upward c Don t use TOP 2nd ring by mistake 2nd ring is tapered inner cut Broken piston ring lands Worn ring groove l EN Replace the gt Note for piston or ring replacing Heat the piston before inserting the piston pin 98 Troubleshooting 3 Recoil too heavy Final steps 99 1 Load W kg Obtain 0 016 x C LoadWkg Small pulley dia 13 t4 17 0917105 Bet ype w 13w t5W mm 18 23 27 0136 160 Measure the load when belt deflection is omm If the load falls between W and 1 3 x W as s
2. 18AH 24AH 30AH 35AH 40AH 45AH LAOAE LABAE 10 C 14 F or higher 3o C 22 F orhigher L60AE L7OAE 10 14 F or higher 30 C 22 F or higher L75AE L100AE 10 C 14 F orhigher 30 C 22 F or higher 2 Battery cable To connect the battery to the starter thick and short wires must be used low voltage cables for automobile AV wire Using wire other than that specified may cause the following troubles Wire thinner than Single conductor wire specified Wire longer than specified ues Open circuit caused by vibrations Low current _ Faulty starting Faulty charging Checking and Servici 2 Battery inspection 1 Check the electrolyte level in each cell If the level is insufficient add distilled water to attain the upper limited level Electrolyte level Check the electrolyte level every 7 to 10 days The electrolyte must be kept 10 20 mm 0 3937 0 7874 in over the top of the plates 2 Check the battery case for loose parts cracks or flaws 3 Check the battery terminals for looseness and rusting 4 Check the battery cap for clogged vent holes 5 Test each cell by drawing electrolyte into the hydrometer Specific Gravilty 1 27 1 29 Type II 1 26 1 28 Type Note Hydrometer El ctrolyte Variation of Specific Gravity with Temperature
3. 3 Connecting the piston and connecting rod Line up the position of the piston top mark and the matching marks on the connecting rod as shown in the illustration When inserting the piston into the cylinder position the piston top mark so that it faces the crankcase cover side gear box Piston top mark LAOAE L70AE Through bolt o 2 ban Line up the piston and connecting rod 47 Checking and Ser Piston top mark Piston top marks are stamped as shown below depending on specifications S spec or D spec and piston selective fitting with the cylinder block mm in mm in Piston Piston O D biog S spec D spec Classification of ID 40 015 0 0006 91095 309290 oF less d ss ps 40 005 5 D 40 020 0 0002 010008 oF more sm DM 0 0008 2008 or more D 0 0002 0000 or more 0 005 T less than lessthan 10 010 0002 0 005 0000 D 0 005 oe 40 0 0006 9 more 0 0002 oF more d standard diameter Refer to Page 32 The piston is selectivery fitted with the cylinder block as indicated by the arrow mark in the above The piston for servicing is supplied in SM or DM irrespective of 1 0 of the cylinder block 48 Cher and Servicing 44 CRANKSHAFT MAIN BEARING AND FLYWHEEL 1 Crankshf
4. Improve the means of starting dynamo 102 Troubleshooting 6 Normal fuel injection and compression and light recoil but engine is still hard to start If the engine is hard to start even when in jection and compression are normal the re coil is light and ambient temperature are normal check the following in order Causes and Remedies Main causes Remedies Special Instructions 1 Improper fuel oil 1 Low quality fuel 2 Water in fuel 1 Use a different fuel 2 Replace fuel 1 Using the recommended fuel oils 2 Observe proper handing storage and draining procedures 2 Incorrect timing of opening and losing of intake and exhaust valves 1 Valve head clearance too large 1 Adjust intake and exhaust valves 1 How to adjust intake and exhaust valves 3 Inaccurate injection timing 1 Improper thickness of adjusting shim 2 Improper injection pressure 8 Worn plunger 1 Adjust thickness of adjusting shim 0 Adjust injection pressure 8 Replace plunger 1 Adjust injection timing 2 How to adjust injection pressure 8 Proper handing of fuel 4 Faulty spray from fuel injection valve 1 Nozzle valve sticking 2 Flaw on nozzle valve 3 Low injection pressure 4 Worn nozzle valve 5 Clogged injection hole 1 Wash or replace valve 2 Replace valve 3 Adjust injection pressure 4 Replace valve 5 Wash or replace va
5. L C 5 3 Racing If engine starts racing during startup or op ued running can lead to major troubles eration stop the engine immediately with the Racing is due to a malfunction in the governor regulator or decompression lever Contin system Possible causes When governor handling is operated Racing Alter re assembly to fuel Improper adjustment of injection pump governor lever or improper assembly of governor Suddenly during operation Causes and remedies Main causes Remedies Special Instructions 1 Regulator handle operates too fast Adjust governor lever Proper operation of control handle Check and adjust position of regulator How to adjust governor lever sppring 2 Improper adjustment of governor lever 1 Improper adjustment Adjust governor lever How to adjust governor lever 2 Loose on pump adjusting lever 3 Governor weight malfunction 1 Governor weight malfunction 0 Repair 105 Troubleshooting 5 4 Uneven Rotation Uneven rotation hunting lowers engine performance and work efficiency Main causes of uneven rotation are Improper governor adjustment Improper sliding of governor lever shaft Periodic fluctuation of rotation Malfunction J Large gap between pump adjusting lever related to and linkage screw governor Too much play in governor spring Governor spring mounted incorrectly Bluish white Imp
6. E Installation of lubricating oil pump Checking and Servicing Oil pump mm in Model L40AE LT00AE item Standard Service limit 28 96 28 98 28 90 Outer rotor O D 1 1402 1 1409 1 1378 29100 29 121 29 18 Outer Housing 1 0 Crankcase cover 1 1457 1 1465 1 1488 Clearance between housing LD and 0 120 0 161 outer rotor O D _ 00047 0 0063 7 97 8 00 7 90 Ober and Inc fotor weh 93138 03150 03110 802 805 8 10 03157 03169 _ 0 3189 Clearance between housing and 0 02 0 08 ES inner outer rotors 0 0008 0 0031 Clearance between the inner and outer rotor 60085 ones 57 Checki Servicing 4 10 FUEL SYSTEM 1 Fuel injection pump 1 Specifications Model YPFE M Model hem L40AE L48AE L60AE L7OAE L75AE L90AE LIOOAE Stamped Bare engine 40S ss 65 705 758 905 1006 mark Generator set 400 480 600 70D 75D 90D 1000 CAUTION 1 The ID marks for stamped the pump is on the pump mounting flange 2 None of these fuel injection pumps is inter changeable 3 The fuel injection pump for discrete engine differs from the generator in the direction of the fuel inlet pipe L40AE LI00AE Adjusting Shims Standard thickness shop assembly 05 0 0197 Configuration of fuel oil pump Checking and Servicing
7. MiSx15 LA0AE LABAE 14 M6x 10 0975598 Hexagonal dimension 10 Crankcase cover bolts X LOAE LIOOAE 13 MB x 1 25 020 180 Hexagonal dimension 12 Stifener bolts on crankcase 200 230 LAOAE LIO0AE MB x 125 estes LAOAE LABAE 4MBx125 Head stud bolts stud side L60AE L70AE 4 M9 x 125 hence Apply screw locking agent L75AE LIOOAE 4 10 15 IUS Apply oil to the face of the 280 320 LAORE 148 4MBxi125 Threaded par 205 231 Hexagonal dimension 12 Cylinder head nuts L60AE L70AE 4 9 x 1 25 Hexagonal dimension 14 L75AE LI00AE 4MT0x 15 O90420 Hexagonal dimension 17 FO nozzle case nut L40AE LIOOAE 1 0 606 40UNS 28 Ee Hexagonal dimension 15 FO pump delivery holder L40AE L100AE M14 x15 9 Hexagonal dimension 17 FO pump stud bolts 70 100 i s L40AE LI00AE 3M6x10 Apply screw locking agent 1 FO pump nuts L40AE L100AE 3M6x10 CRAT Hexagonal dimension 10 FO nozzle bolts stud side L40AE L100AE 2 6 10 6122 Apply screw locking agent FO injection nozzle nuts L40AE L100AE 2M6x10 bec Hexagonal dimension 10 Apply to the face of the L40AE LZOAE 2MTX10 iiss threaded part Connecting rod bolts amp Hexagonal dimension 10 L7SAE L100AE 2M8x10 75 555 Hexagonal dimension 13 Notes 1 For bolts and nuts marked apply engine to the thread and seat 2 For bolts and nuts marked apply screw locking agent to the thread before threadin
8. 1 Fuel tank is empty 2 Fuel cock closed 3 Clogging in fuel strainer 1 Air in fuel pump Push decomp lever and pull recoil several times with no compression Hold the high pressure pipe in the same hand as the decomp lever Prime and bleed air Remove the fuel injection pipe Loosen the delivery valve retainer removal not necessary se AAR Methods J c Open the fuel cock to flow fuel Remove fuel injection rotate flywheel half way when no pipe fuel flows d Tighten and test delivery valve No fuel flows through E check tightening torque delivery valve of fuel pump Replace delivery valve as a 95 set including packing 2 Dustflaws in delivery valve seat gt Clean the delivery valve 3 Faulty governor linkage adjustment gt Adjust the governor linkage see instructions 4 Wom fuel pump plunger gt Replace fuel pump Troubleshooting 1 Nozzle valve sticking Clean or replace How to test nozzle valve a Clean with diesel light oil b Put valve nozzle tip into valve holder c The valve is normal if the nozzle valve falls smoothly into the valve body by the force of its own weight 2 Improper injection pressure Adjust the injection Injection pressure pressure with 100 high adjusting shims Check Knocking occurs Fuel not injected or Shims 0 15 0
9. 3 Disassembly and reassembly This is standard fuel injection pump body Disassemble and reassemble the fuel pump in the direction order of UP DOWN and SIDE from the center of the fuel injection pump body marked C as illustrated Reassemble the gasket A andB for the delivery seat in the position at the time of disassembly Suction pipe joint NOTE See the position of mark Never remove the suction pipe joint from the pump body during routine disassembly Symbols Directions of disassembly from the center of fuel pump body C Up em se e 59 T 21695474 Delivery spring Fuel pump disassembly and reassembly Delivery valve holder torque 300 Song sn Checking and Servicing 2 Fuel injection valve 1 Specifications Model YDLLA P tem Speciication 40AE 4BAE L6OAE L70AE 175 1100 Mark to identify assembly AN AF YANMAR YANMAR YANMAR Mark to identity nozzle vae and pony body 224 1 21480 22480 Example 2 Check Symbol 150P indicates an injection angle of 150 1 Carbon deposits symbol 224Al implies 4 nozzle holes which are Flowering 0 22 mm in injection hole diameter Position of ID mark of assembly Position of ID mark of nozzle valve and nozzle body Structure of injection valve CAUTION 1 When replacing fuel inje
10. 22991 23000 2291 LiO0AE 0 9052 0 9055 0 9020 Piston and rings si ring side clearance LA0AE 0065 0095 0 15 ring width and ring groove L100AE 00026 00037 0 0059 2nd ring side clearance LAORE 003 0065 015 ring width and ring groove LI00AE 00012 00025 0 0059 ring side clearance LA0AE 002 0055 015 ring width and ring groove L100AE 00008 00022 0 0059 Piston ring 27 29 252 LAE o1063 0 1140 0 0962 30 32 277 8 0 1181 0 1260 01091 LG0AE 32 34 297 al L7OAE 0 1260 0 1339 0 1169 1 T dimensions T 33 35 wing L75AE 01299 01378 0 1209 34 26 7 L90AE 0 1339 0 1417 0 1248 36 38 3 37 LI00AE 0 1417 0 1496 0 1327 ions 140 1 470 1 485 1 36 Bdimensions 1100 0 0579 0 0585 0 0535 T 275 295 275 LAOAE 91083 01161 0 1083 30 32 277 14 0 1181 0 1260 0 1091 rJ 32 34 E T dimensions U 33 35 3 07 AAE 04300 01378 0 1209 2rid ring 34 36 347 190 01329 01417 0 1248 36 38 337 LIOOAE 0 1417 0 1496 0 1327 140 1470 1490 136 L7OAE 00579 00587 0 0535 B dimensions L 3 L75AE 1 970 1 990 186 L100AE 00776 00783 00732 11 Service Standards Parts Model Standard Service limit Remarks Piston ring 26 28 249 L40AE 01024 01102 0 0980 20 24 199 LABAE 00787 00945 0 0
11. Checking and Servicing Cylinder sleeve 1 mm in Standard Servie limit L40AE 6771 2573 26835 EENES 29528 23899 23590 L70AE 65070 50720 9779 U75AE 1469 5 1800 3156 L90AE 16 25808 35870 23929 4 9 LUBRICATION SYSTEM This engine adopts a forced oil lubrication sys tem driven by a trochoid pump Lubricating oil is circulated as follows The rocker arm chamber is lubricated by moisture LO filter Trocoid pump Crankshaft Crankpin metal Crankcase cover Retethole LO pump EL pump LO fiter 60 mesh rasin Lubricating oil route 1 Lubricating oil pump 1 Measure the clearance between the outer rotor and body crankcase cover Replace the pump if the clearance exceeds the al lowable limit 2 Measure the clearance between the outer rotor and the inner rotor with a thickness guage Replace the pump as a set if the clearance exceeds the allowable limit 3 Installing the lubricating oil pump 1 Insert the lubricating oil pump assembly D from the outside of the crankcase cover Coat the rotor with oil before in stalling the cover 2 Insert the parallel pin C into the lubri cating oil pump shaft 3 Set the weight on the gear 4 Insert the spindle into the weight then push the spindle into the shaft Once in place the spindle cannot be removed ol L
12. Description lustration Dial gauge mm n measure bending and 1div 0 01 0 0004 gap of the shaft surface Range 0 5 0 0 197 distortion etc 9 10 90 0394 mm nj Test indi To measure positions idw 001 0 0004 Range 0 08 0 0 031 normal dial indicators mm in Magnet stand To attach dial indicators to d Main bar Sub bar various positions for easy xiength dia xlength accurate viewing 12x176 10x165 0 472 6 929 0 394 x 6 496 y 14x183 12x165 0 551 x 7 205 0 472 x 6 496 Micrometer Range mm n To measure the O D of 0 25 0 0 984 the crankshaft piston 25 50 0984 1 969 piston pin etc 50 75 1 969 2 953 75 100 2 953 3 937 Cylinder gauge Range mmn To measure the I D of the 10 18 0294 0709 18 35 0 709 1 378 beaings 100 x50 x55 8937 x 1 9685 x 2 165 in Depth micrometer To measure value sinkage Range 0 25 0 0 984 and liner projection Square To measure the inclination Size 100 8 937 of valve springs and Squareness of various parts V block Use when measuring the bending of a shaft Disassembly and Reaseembly Ed Description Mustration Torque wrench Rage Use when tightening omn lb ft bolts and nuts with eu 40 300 0236 0551 29 217 30
13. Piston 0 B Push bolt type Washer Only LIOAE L70AE Nut Cap Check of crank pin metal 2 Measuring clearance between crank pin and crank pin bearing metals Use plastigage 1 Remove the bearing cap and wipe the from the bearing metals and crank pin 2 Insert a plastigage into the cap on the large end in the crankshaft direction 8 Attach the connecting rod to the crank pin and tighten the connecting rod to the specified torque 4 Remove the rod and measure the crushed plastigage with the measuring Measuring scale Measuring the crank pin metal clearance 46 Checking and Servicing Yp Tightening torque kgcm Clearance between crank pin and metal mm in Model LAR ORE mm L4OAE L7OAE L75AE LIOOAE Connecting 180 210 575 425 0 025 0 050 0 033 0 062 rod 30 152 271 307 Standard 0 0010 0 0020 0 0013 0 0024 Service limit d Measuring clearances between crank pins and 0 0047 crank pin bearing metals Line up it using the undersized crank pin metal if it exceeds the service limit Undersized crank pin metal Part No ne Migal L40AE 148 L60AE L70AE L75AE L100AE Standard 714250 23600 714350 23600 714650 23600 Under size 0 25 mm 0 0098 714250 23610 71430 23610 714650 23610 Under size 0 50 mm 0 0197 714250 23620 714350 23620 714650 23620
14. Gap 28 334 00 An asterisk indicates a characteristic in tt 13 warm stato ambient temperature 20 C charging rises 1000 pm at 13V E Atowabie ambient 20 4850 Combination of regulator Model 2 Staring motor I O8 1 Be sure to ground both engine and engine driven machine 2 Section enclosed with dotted square is pre wired at Yanmar factory 3 Locally procure 1 Battery LAOAE LAGAE 18 24AH LGOAE 70AE 24 36AH L75AE L100AE 36 45 AH 2 Battery cable 6 amp AV20 Starting switch and 4P coupler 65 Checking and Servicing L40AE 100AE ENGINE WIRING DIAGRAM For 12V 1 7A Chart ole loy CB Fomalo Recepaco EA Eyes ux Notes Model GPosos B Output current 16 18A DC 07 134 DC Hp fat 12V atiav An asterisk indicates a characteristic in charging 1000mm 1500 arm stale ambient temperature 20 C san 4499 E ambient T 2 temperature 20 4680 20 465C Combination of p regulator Model 50 Staring motor CELI 1 Be sure to ground both engine and engine driven machine 2 Section enclosed with dotted square is pre wired at Yanmar factory 2 Locally procure 1 battery 2 battery cable 3 starting switch and 4 cables Battery L4QAE 48AE 18
15. 0 5 0 8 0 02 0 03 Repair limit mm in 0 2 0 008 T 12 450 12 468 Shaft diameter mm in Brush side bearing 0490 0401 Bearing inside diameter 12500 02938 12 450 12 468 Shaft diameter mm in Pinion siding 0490049 Standarg 589001 Pinion inside diameter mm n 14522255 12 450 12 468 Shaft diameter mm in ly 490 0401 Pinion side bearing I Bearing inside diameter 12500 12518 0492 0 Front Pinion side 60040DU Clutch bearing Rear C 690422 Armature bearing Front Pinion side 69037 Rear 6082 Checking and Servicing 3 Generator Dynamo Regulator and Rectifier The standard dynamo for the L A type engine rated at 12V 35W 12V 40W 6V 15W which are manufactured to the electric starting specification used exclusively for lighting of engines to the is rated at 12 V and Optionally available are recoil S specification dynamos of the 12 V system which are rated at 1A 1 7A and 15A Also available are dynamos e Recoil specification LA0AE L70AE 1 Specifications Model GPesss GP9589 GPess7 9595 GP9591 Type Magnet system lt lt lt Combination Regulator RS5112 2 RS5112 3 lectifier ZR2117 ZR2120 Half wave Full wave oc 1 8 18 1326 33 1214 8 Output 3600 1310 13
16. 10863 12000 125 14274 1498 1434 10563 1200 180 240 0428 0472 0492 0562 0590 0565 0416 0472 0709 0545 12701 14000 145 165 1744 1655 12701 1400 2100 2829 0500 0551 0574 6559 0687 0652 0500 0580 0827 1102 1269 1207 M10 125 0497 0475 1781 1717 E 0701 0576 Table 1 3 Procedure for using helical insert 2 Tapping part 1 Drilling When using the helical inserting part it is necessary to drill a guiding hole which is slightly larger than the nominal diam eter because the insert occupies the space between the bolt and threaded hole The size of guiding hole should be B which is the usual guiding hole size A plus twice the height of the thread c This slightly exceeds the outer diameter of the bolt threads When drilled with a size B drill the original female thread coil is completely stripped off The new guiding hole must be drilled ac cording to the depth calculated from the effective thread length of the bolt If the drill hole is countersunk or spot faced the depth should be increased accordingly 115 After the driling the hole must be tapped with helical insert taps A helical insert part will be fitted into this new hole and the inner thread matches the originally tapped hole to accept the original bolt The tapping depth depends on the effective thread length of the bolt The helical insert tap pi
17. 15016 15034 cylinder block side Bearing LD 064205919 LAOAE 0 016 0 045 1100 0 0006 0 0018 140 24980 24993 24 90 L4BAE 09835 09840 0 9803 Ball bearing on Stem O D 160 29 980 29 993 29 90 crankcase cover side L7OAE 11803 11808 1 1772 L7SAE 34980 34993 34 90 LI00AE 13772 13777 1 3740 LAOAE 24990 25000 2502 L4BAE 09839 09843 0 9850 LGOAE 29990 30000 30 02 Bearing lD L70AE 11807 14811 1 1819 175 34990 35000 25 02 Ball bearing on L100AE 13776 13780 1 3787 crankcase cover side LABAE 180 L0 020 0 030 T 0 08 0 10 L Loose fit dearance L7OAE 0 0008 0 0012 0 0031 0 0039 T Tight ft L7SAE LIOOAE Thrust clearance L40AE 0040 0280 045 Gap of axial direction LI00AE 00016 00110 0177 _ Tappet 0 6960 6980 687 StemO D pag 02740 02748 0 2705 Tappets for IN Hoeda L40AE 7000 7015 7 06 EX valves Cylinder block 100 02756 02762 0 2780 clearance 140 140 23 89 L100AE 0 9405 Tappets for fuel dia LAOAE 24 06 injection pump Cylinder block L100AE 09472 14 Service Standards Unit mm in Pans Model Standard Service limit Remarks Crankcase cover L40AE 34000 34025 E L4
18. 2 Loose end nut 1 Replace side cover packing 2 Increase tightening torque 1 Pulley centering and adjusting of belt tension 2 Stress importance of regular re tightening 106 Troubleshooting 5 5 Output Drops When an engine is required to work beyond its capacity rotation speed drops and it emits a thick If this happens during black exhaust smoke Check the following Abnormal exhaust color black or bluish white Output drops Abnormal operating sound other than exhaust Causes and remedies cause Improper fuel injection Pressure leak Fuel related problems Air cleaner cloggin chamber Clogging in cooling air intake Clearance between intake exhaust valves too large Bearing metal sei Lineripiston seizi Carbon deposite in combustion normal load operation something is wrong with the engine Turn of the engine and try to find the ing and ing Main causes Remedies Special Instructions D Improper fuel injection 1 Nozzle sticking 2 Worn nozzle 3 Low injection pressure 4 Worn plunger 5 Insufficient tightness in delivery valve 6 Improper governor adjustment 7 Nozzle injection hole clogged 1 File or replace 2 Replace the nozzle 3 Adjust injection pressure 4 Replace the nozzle 5 Repair or replace Adjust governor 7 Wash or replace nozzle 6 Handling fuel oil 6
19. 254455 214 218 400 57 114250 923901 075120799 421004 0843 0460 193492 254 256 214218 114268 92300 0752 0 756 171 004 0 843 0 850 251 252 504205 265271 5 11480 22901 0980 0992 197 1200 059 1097 255 256 304 805 269 27 31436 82900 1 004 1 008 1 197 1 201 1 059 1 067 Chanfecby sand paper 301252 354355 314 316 114650 92300 1185 1180 1394 1390 1236 1244 255255 554455 205 301 114668 92300 10541009 1394 1398 1 177 1 185 Valve stem seal fitting tool Material steel Scale free casico 02 sons Gb 05 Uni mm n Dimensions 4 4 55 555 3052 120 122 3537 i 02165 02171 0354 0362 0 473 0 480 0 374 0 382 60 605 9507 130 132 8587 n 0 2362 02368 0374 0382 0 512 0 520 0 335 0 343 70 7015 115 117 140 142 7 114650 92350 2756 02762 0453 0461 0551 0559 0255 0303 120 tails of Special Tools Flywheel tightening handle Material steel Scale free Unit mm in 1890 B 88 5 s 3 910 holes 3 404 holes ME 4 97 holes 4 4028 holes 4 3 47 holes 3 90 28 holes 5 Flywheel extractor Material steel Scale free Unit mm in 13 410 holes 3 404 holes 121 YANMAR CAGIVA SPA Via Carabelli 7 9 21012 Cassano Magnano Varese Telephone 4
20. En 18 1326 33 1214 8 16 Tom REN 6V 15W lamp 20 C votage lamp 13V 40W evo 4 12 5 15 zx T Clockwise Direction of rotation e At charging start rpm 5100 st000 at 12 V Regulated voltage on regulator na 14 5 0 5V lt Permissible ambient temp C 20 65 1 Covered wire Green White and Red and Black Color 2 wrie Green White Tube Black Black Yellow Yellow forelectric tor electric for electric for electric only for light starting starting or starting starting ingof engines Remark for lighting standard or to the recoil ofengines for lighting of S spec to the recoil engines to the S spec recoil S spec Notes The dynamo may be combined with 1 955133 type regulator with a builtin safety relay drive circuit 2 952190 type regulator without the charge lamp circuit or 3 RS5110 type regulator with a built in safety relay drive circuit and 4 The dynamo used only for lighting of engines to the recoil S spec is equipped with neither a regulator nor rectifier and outputs AC voltage Servicing 2 Construction The dinamo is composed of the starter coil and rotor the stator is bolted to the cylinder block and the rotor to the flywheel 3 Generator check Follow the directions to check whether the generator works n
21. Malfunction of magnetic switch gt Check wiring to magnetic switch 6 Pinion incorrectly engaged Adjust dimension when pinion comes 7 Discrete starter turns when its M terminal is connected Y Yes Replace magnetic switch whose 1o battery contact is faulty 8 Engine seizure Check engine Replace as required Starter 1 Refer to items 6 listed above itself turns gt but engine 2 Broken pinion roller clutch Check pinion roller clutch Replace if will not necessary 1 Refer to items 1 and 2 listed above 2 Engine oil has abnormal Starter viscosity Replace engine with proper one turns 3 Engine is overloaded by Check clutch for ON OFF operation sluggishly driver machine gt Check drive belt for tension 4 Engine encounters great Check engine Repair it or replace roded terminal charged battery refer to 5 necessary Repair wiring sary Repair wiring Repair if necessary out Check shift lever for deformation return spring for fatigue and pinion for slid ing Repair replace as required Correct engagement of pinion with ring gear Replace if necessary No Replace rotor and or starter defective parts Most starter failures are attributed to damage caused by an overrun and a fused contact of the magnetic Switch The following table enumerates the symptom condi
22. so take care to reassemble correctly as the improper ex ample shown in Fig f Direction of rotation 2 Assembling procedures 1 Check that the spring is set correctly in the starter case housing Adjust the shape of the inner end of the spring to locate it at about 4 mm from the starter shaft for mak ing the reel s hook engages with the spring correctly The inner end of the spring can be simply reshaped by pliers for a length of about 10 mm Spring outside end Good Hook of reel Improper 0 35 3 Hold the starter rope as shown in Fig h Wind it 4 turns in the arrow direction while securely holding the reel so that the rope may not be reversed Lead the starter rope from the inside to outside Slowly turn the reel in reverse 4 Assemble the removed parts in the reverse order of the disassembly in Fig g When setting the friction plate first set the return spring slightly lift and then insert it into the mating hole of the friction plate as shown in Fig h and i Turn the friction plate a little to the arrow direction When the ratchet boss aligns with the guide assemble the thrust washer and the E ring nut for 160 and upper mod els while securely pressing down the fric tion plate to the reel Place the E ring in the groove of the starter shaft once manu ally and then fasten it with the pliers Direction of rotation for D spec Direction of rotation N for
23. 0 08 mm 0 0031 in Checking and Servicin 2 Depth of commutator insulating material Check the insulating material for depth The depth is within a range from 0 5 to 0 8 mm the commutator is acceptable Correct with a hacksaw blade when the under cut is too shallow 0 2 mm tolerable limit 2 Short circuit test Check the continuity between the yoke and any field coil terminal Continuity indicates that the coil is shorted and it must be replaced 3 Cleaning the inside of the yoke If any carbon powder or rust has been deposited in the yoke blow the yoke out with dry compressed air mm in Do not remove the field coil from the Maitenance Repair yoke standard limit Insulating See separate service data material P 83 2 Field coil 1 Open test Check the field coil for disconnection and grounding Check the continuity between the termi nals connecting the field coil brushes Continuity indicates the coil is opened If 3 Magnetic switch not replace the coil 1 Shunt coil cotinuity test Check the continuity between the C ter minal and the magnetic switch body metal part If discontinuity is detected replace the magnetic switch whose shunt coil is disconnected 78 Checking and Servicir contact is faulty and that the contactor must be replaced Col resistance 20 88 060 2 Series coil continuity test 4 Pinion Check
24. 24 AH LGOAE 70AE 24 36 L7SAE 100AE 36 45 Battery cable amp amp AV20 66 Checking and Servicing L40AE 100AE ENGINES WIRING DIAGRAM with air heater and timer For 12V 15A 12V 3A Charging Generator 67 White GW Green tihite Timer 15 sec C8104 CAT04 CATO4 CBI04 12 En care e Me Cerone Receptacle type T Airheater 055 NU 4 Be sure to ground both engin ngine driven machine Section enclosed with dotted square is pre wired at Yanmar Battery LAOAE A8AE 30AH LEQAE 70AE 35 L75 100AE 45 Battery cable AV20 lt 1 3 AV30 23m Starter cables and shall have total resistance below 5 100 provided that terminal resistance shall have 15 1000 per connector while screwin connector 0 0 Key switch connections Presheating OO or joj o Saw O Toroo Checking and Servicing L40AE L70AE ENGINES WIRING DIAGRAM Generator for Lighting For 12V 25W 40W Use lamp only amp 12V 250 or GP9589 122041055227 For 6V 15W Use Lamp only Magneto generator Lacu Ground Notos 1 Use Lamp only 2 For Recoil starting specification engine 3 Color code GW GreonWhio R Red B Black Terminal CAIMale
25. 5 960 590 us L7OAE 02341 02346 0 2323 175 6945 6960 6 90 L100AE 2 734 2 740 0 2717 Valve spring T Laoag Bret 28 1 102 26 5 1 043 Free length UE 029 31 5 1 240 L75AE 40 1 575 39 5 1 555 Service Standards Unit mm in Parts Model Standard Service limi Remarks Valve spring T 075 0 030 inclinat L60AE Inclination Gone 0 6 0 024 LISAE L100AE L40AE L48AE LeoAE Spring constant kg mm E 175 180 251kg LHOOAE 397 551 B Intake exhaust valve rocker arm rocker shaft and push rods LAOAE 11989 12000 1190 IN EX valve rocker L70AE 0 4720 0 4724 0 4685 am shat 0 0 175 14989 15000 14 90 LIOOAE 0 5901 0 5906 0 5866 140 12016 12034 1210 L7OAE 04731 04738 0 4764 IN EX valve rocker arm I D 175 15016 15034 15 10 L100AE 0 5912 0 5919 0 5945 140 1298 1302 LABAE 5 110 5 126 160 1623 1627 Push rod length L7OAE 6 390 6 408 L7SAE 1968 1972 0 7748 7764 stort LAOAE 005 L100AE 0 0020 Valve clearance intake and exhaust hern 00059 Standards Seite Stantlards Unit mm in Pans Model Standard Service lim
26. 5748 Fitting 0002 0025 m 10 007 0 090 0007 0030 0 00006 0 0010 0005000122 00003 00012 3 The ball bearing on the flywheel side has been press fitted onto the crankshaft Replace the crankshaft assembly if it is loosened 49 2 Main bearing metal 1 Checking the metal metal on the crankcase cover side Replace the main bearing metal if it is discolored separated or damaged in any other way The main bearing metal has been pressfitted into the crankcase cover Align oil hole in the metal with oil groove as illustrated be low CAUTIONS 1 Mount the metal so that the oil groove faces up 2 The sinkage should be 1 mm 0 0394 in from the thrust surface Checking and Servicing Carefully fit the main bearing metal so that the oil groove is on the upper half Align the oil hole in the bearing metal with the oil groove Positioning the main bearing metal Measure an oil clearance between the main bearing metal and journal If an oil clearance exceeds the allowable limit add an undersized bearing metal shown below Under size crank pin metal Part No Model item L40AE 148 L60AE L70AE L7SAE L100AE Standard 114250 02100 114350 02100 114650 02100 Under size 0 25 mm 0 0098 in 14250 02200 114350 02200 11450 02200 Under size 0 50 mm 0 0197 in 114250 02210 114350 02210 114650 02210 3 Flywheel 2 Ring gear 1
27. 6 holder Nozzle valve injection not normal mm 04 07 tightening wears 05 08 torque 100 quickly Injection pressure 200 kg cm 3 nozzle Number of injection holes 4 Lifes Clean the element in the fuel tank when replacing the nozzle valve Re align knock pin when replacing nozzle valve 4 Improper nozzle assembly Re align knock pin 5 Nozzle injection hole clogging Final steps L Clean or replace Troubleshooting _ _ 2 Low compression pressi re Trouble 1 Leak in intake and exhaust valves Incorrect valve Adjust to proper head clearance gt valve clearance intake and exhaust valve Methods a Tum the flywheel so that under com pression the TD matches the aligning mark fin cutting mark on the cylinder b Adjust using adjusting bolt When engine is cool 0 15 mm Check adjust every 500 hours of operation Wom valve seat valve guide 5 the intake exhaust valve seat Seat angle 90 Seat width 1 5 to 3 0 mm Keep intake and exhaust valves separate 2 Leak from around the fuel injection valve Improper tightening of injection valve gt Increase tightening torque all around retainer Make sure the front and back surfaces of nozzle retainer Defective heat insulating gasket Replace the gasket 3 Leak through gasket
28. 68 3 Permissible angle of inclination deg 20 momentary 30 Balancer shaft Single shaft Specifications 160 L7OAE D S sE TS E Single cylinder vertical 4 cycle air cooled diesel Cooling system Forced air cooling by flywheel fan Combustion system Direct injection system Starting system Recoil staer Qh Recoil staner staring motor Number of cylinders Bore Stroke mm in PER ori eat Displacement 7 cuin 0 273 16 66 0 296 18 06 Continuous 4 0 5 5 44 6 0 Supe Maximum 4 4 60 49 67 Speed PTO shaft mpm 3600 1800 3600 1800 3600 1800 3600 1800 Speed at no load max min 08975527 3 977972 79977325 22 Compression ratio 195 PTO position Crank Cam Crank Crank Cam Crank PTO shaft Direction ot revolution Counterclockwise viewed from PTO shaft Fuel injection pump Bosch type YANMAR PFE M type Fuel injection timing FID bTDC dan Fuel injection nozzle Hole nozzle YANMAR YDLLA P type Fuel oil Fuel injection pressure Mpa 19 6 200 Fuel oil selection Diesel fuel BS 2869 A1 or equivalent Fuel oil filter Paper element FO tank built in type Fuel oil tank capacity 05 gal 3
29. 8 Starting motor Only for starter motor specification Remove the starting motor 9 Valve rocker arm cover Remove the valve rocker arm cover 10 Valve rocker arm assembly Remove the valve rocker arm assembly Disassembly and Reaseembly Removing the valve rocker arm assembly 11 Push rods Pull out the push rods 12 Fuel injection valve 1 Remove the fuel injection pipe 2 Remove the fuel injection valve e if the valve is tight loosen the nuts using a wrench with the fuel injection pipe set 4 Be carefuly not to damage the nozzle gasket insulator and nozzle spacer we e TO Nozzle gasket Fuel injection valve disassembled Disassembly and Reaseembly 13 Cylinder head 1 Remove the cylinder head Keep the combustion surface faced up 15 Crankcase cover 1 Remove the oil pump cover 2 Remove the oil filler cover 3 Remove the crankcase cover Removing the cylinder heed 14 Fuel injection pump 1 Remove the fuel injection pump Remove the pump together with the base plate Make sure the hooking of control lever in rack before disassembly e Pull out any remaining flat tappet Removing the fuel pump 27 16 e Step 1 and 2 should only be done when necessary e Be carefuly not to damage the oil seal Removing the crankcase cover Camshaft Pull out the camshaft Check the timing mark Keep exhaust and intake tappets sepa rate They may
30. Adjusting governor O Pressure leaks See 5 1 2 Fuel related problems 1 Low quality fuet 2 Out of fuel 8 Fuel strainer clogged 1 Change to specified fuel 2 Add fuel and bleed air from fuel pump 3 Clean inside fuel tank and clean or Use the specified fuel Proper handling of fuel valves too large replace fiber element Air cleaner element clogged Clean air cleaner Handling of air cleaner Carbon deposits in combustion Remove carbon Handling of fuel chamber Clearance between intake exhaust Adjust the gap Adjusting intako oxhaust vale clearance Malfunction of moving parts 1 Seizing wear of cylinder lineripiston 1 Repair or replace 2 Selzing wear of crank pin Repair or replace 6 Ig wear of crank bearing 3 Repair or replace Handling of lubricating oil 4 oizing wear of piston pin 4 Repair or replace sufficient cooling air 1 Clean cooling air inlet 2 Clean cylinder rib 107 Troubleshooting 5 6 Sudden Stops during Operation Sudden engine stops during operation are usually due to seizures of moving parts be cause of improper cooling or lubrication These in turn are caused by carelessness Once the engine breaks down repairs are costly and time consuming To avoid these problems take good care of your engine the part of the operator Clogging in cooling air inlet
31. Battery temperature vs i specific gravity Specific gravity os Wo ay G6 Gr arc Electrolyte temperature Do not overfill the battery Wipe up spilled electrolyte at once and flush well with water 4 The specific gravity varies with the tem perature as shown in the accompanying table e The battery must be replaced if sulfation is evident The battery must be replaced if there are pastes settled on the bottom of each cell 91 Checking and Servicing WARNING 1 Carfully protect yourself and your clothes against the battery electrolyte which is diluted sulfuric acid hard enough to injure the skin and eyes If any injury is anticipated consult the doctor at once When using the dynamos combined with a regulator on the engine carefully check the battery for terminal voltage If the terminal voltage is too low the regulator works so that the dynamo fails to supply the voltage about 6V or more required to charge the battery If so use a battery charger Battery charging Remove the battery remove the cap from each cell 2 Connect the charger positive cable to the battery positive terminal 3 Connect the charger negative cable to the battery negative terminal e Charging current Battery current 20 hrs rating 10 hrs rating Example 20 hrs rating 45 AH battery 45 20 45 10 2 25A 4 5 Charging Charging the battery until
32. EXP 177110 at 3600 rpm 1 Be sure to ground both engine and engine criven machine 2 Section enclosed with dotted square is pre wired at Yanmar factory Section enclosed with alternate long and short dash line is the section included in engine packing For this section purchaser is expected to 1 Connect coupler 2 Secure charge lamp ground LA106 with bolt 6 3 Locally procure 1 Battery LAOAE 48AE 18 24 AH 160 70AE 24 36 L7SAE 100AE 36 45 AH 2 Battery cable 8 AV20 lamp switch and cable AV1 25 Take off power for the lamp through the female box terminal 8104 Procure the lamp and switch at your specification 13V 3 0A engine revolution 3600 rpm 20 C 13V 1 143 engine revolution 1400 rpm 20 C Length of wiring harness between key switch and coupler is 700 mm 29 134 When installing the engine according to the vibration proof specification use the cable in sufficient length to prevent disconection 64 Checking and Servicing L40AE 100AE ENGINES WIRING DIAGRAM For 12V 3A Charging Generator Charging generator GP9587 ow ow ow ow Regulator RS2190 How Key Switch Functions 5 s BW B R Y 3 w En Bime ipm mone Notes Model GPossr B
33. Low quality fuel oil Change fuel Use of specified fuel D Injection timing too slow Adjust by removing adjusting shims Adjustment of injection timing Failure to check air cleaner 2 Viscosity too low 1 much oil in bath 1 Reduce oil to limit line Handling of air cleaner Periodical check and cleaning Improper lubricating 1 Too much oil in crank case 1 Reduce oil to upper limit of dipstick Handling of lubricating oil 2 Change lubricating Malfunction related cylinder assem by 1 Wearifracture of piston ring 2 Wom piston 8 Wom cylinder liner 1 Replace piston ring Same as above 3 Same as above Handling of lubricating oil Defective valve stem seal having only suction 1 Replace stem seal 110 Test Run 6 Test Run 61 BEFORE STARTING 1 Check bolts and nuts and flywheel rotation 1 Check for loose lock bolts and nuts 2 Turn the decompression lever in the noncompression direction While turning the recoil starter several times pay at tention to abnormal sounds Decompression mechanism 2 Fuel Open the drain cock and run out a small amount of fuel since water and other con taminants settle on the bottom Drain plug Fuel tank assembly 111 3 Lubricatig 1 Use the specified lubricating oil CAUTION Never mix different brands of lubricating oil
34. Name Yanmar code No Description Mustration Thermometer Digital type instantaneously measures temperature in each cylinder using select switch Model BT 800 95500 08000 Sensor CA 64 955000 08640 Sensor Tachometer Photoelectric type Revolving body Reflecting tape is applied to the outside non contacting of the rotating parts to measure RPMs Capable of measuring RPM of reduc Model HT 441 tion gears step up gears and pulleys 95500H T4410 HE B Reflecting Tape Reflecting tape 10 pieces 95500001041 High pressure fuel Measures engine RPM s using pulse system Pipe clamping type High pressure fuel line 955000 01045 E xm B Circuit tester To measure resistance DC voltage voltage DC current and for continuity testing 22 Disassembly and Reaseembly 3 2 TIGHTENING TORQUES Standard bolts and nuts tightening torque M6 70 100 kg cm 5 1 7 2 lb ft 8 180 200 kg cm 13 145 lb ft Where specified torque be Thread No Tightening torque applied dia x pitch kg om 40 LAOAE L7OAE MBx 125 aeree Hexagonal dimension 12 Valve rocker arm support T 430 470 L7SAE LIOOAE moxis 889 379 Hexagonal dimension 14 L40AE L70AE 16 15 Eel Hexagonal dimension 24 Flywheel end nuts 2200 2300 1
35. piston liner seizing Heavy manual Piston liner seizure turning Insufficient lubricating oil 4 Crank bearing seizure 0 Sudden L Crank pin seizure Stops during operation No injection Se 51 1 Out of fuel sound Light manual Insufficient see 51 2 9 turning Not out of I compression fuel With injection Improper sound Sufficient fuel oil compression Causes and remedies Main causes Remedies Special Instructions D Heavy manual turning 1 Crank bearing 1 Repair damage replace bearing 1 Handling of lubricating metal and or change lubricating 2 Same as above 8 Repair flaw or replace liner 2 Crank pin seizure 3 Piston liner seizure operation 2 Same as above 3 Handling of lubricating oil Stress importance of avoiding overload No fuel injection sound See54 1 Improper fuel See 5 1 2 Improper fuel oil 1 Outof fuel 2 Low quality fuel 3 Water in fuel 1 Add fuel and bleed air from pump 2 Change to specified fuel 8 Drain fuel tank and change fuel Overload Reduce load operation Stress importance of avoiding overload 108 Troubleshooting 5 7 Abnormal Exhaust Color Exhaust color is an excellent way to tell what kind of condition your engine is in In normal weather before the engine warms up fully because of incomplete combustion the engine exhausts a black or bluis
36. spec engine D spec incorporated in the crankcase cover Specifications Longitudinal sectional view Fueltank Fuel ler wie net Mal Fuel injection nozze A Fic ftr Connecting rod lt ale Fuel cock WE d Fuel injection pump Balancer shaft 4 972 Speed control uy Govomor lever LJ Specifications Plan view Camshaft P T O S spec Crankshaft P T O D spec Service Standards 2 Service Standards Unit mm n Paris Model Standard Service limit Remarks Intake exhaust valve seats Seat angle 60 90 L40AE 15 30 Sen width LIODAE 0059 0118 Intake exhaust valves amp valve guides 140 03 07 1 0 043 LAOAE 5500 5515 558 148 02165 0217 02197 take L60AE 60 6015 6 08 Exhaust 170 02362 02368 0 2394 175 70 7015 7 08 Li00AE 02756 02762 0 2787 LAORE 5465 5475 540 L4BAE 02152 02156 02126 Intake 160 5 960 5 975 5 90 L7OAE 02346 02352 0 2323 L75AE 6960 6575 690 LO0AE 02740 02745 0 2717 Valve stem 0 0 LAOAE 5 450 5 460 540 148 02146 02150 0 2126 haust LEOAE 5 945
37. specific gravity is 1 270 1 290 at 20 C 68 F Incase of the battery of Type 1 260 1 280 Before charging remove the cap from each cell Keep fire and sparks from a charging battery Turn power on off at the charger not at the battery terminals Discontinue charging if the electrolyte tem perature exceeds 45 C 113 F CAUTION Quick charging should only be done in an emergenecy slow charging is preferred After installing the battery coat the terminals with clean grease 92 Checkir id Servici 4 13 ADJUSTMENT Adjustment of fuel injection timing Fuel injection timing must be precise If it is 100 early or too late a host of trouble will result in difficulty in starting knocking lowered output poor exhaust color etc Correctly ad just the governor linkage assembly and the injection pressure before adjusting the injec tion timing When the engine is used for long periods of time the injection pump plunger wears out and distorts the timing If the plunger is worn replace it and read just the injection timing 1 How to check the injection timing Set the speed control handle to Run Remove the fuel injection pipe and install the injection timing measurement pipe Match the TD position mark on the fly wheel with the V notch line on the cylin der body fin Turn the flywheel first clockwise then couterclockwise about 30 from the TD mark to make sure fuel is in
38. to the speci fied torque Be especially careful with aluminum alloy parts These are easily dam aged Apply engine oil to threaded parts and flange faces before tightening the major bolts to the specified torque Governor or speed control device Reassemble the governor or speed cotrol device if it has been removed 3 Crankshaft 1 Insert the crankshaft 2 Attach the key flywheel to the crankshaft 3 Install the bearing holder 4 sure that the crankshaft has been inserted as far as it will go e Grease the seal lips Apply oil to the crankshaft journal and pin 28 e Damage or scratches on the governor lever shaft can cause hunting and other troubles Be sure to check the position to retain the regulator spring before re moval Installing the bearing holder 3 Flywheel Tighten the flywheel with the retaining tool Tightening the flywheel Flywheel Tightening Torque kg cm 0 0 1 40 170 1 200 1 300 86 8 94 0 IL75AE L100AE 2 200 2 300 159 1 166 3 4 Piston and connecting rod 1 Insert the piston and connecting rod as sembly move the crankshaft to Top Dead Center The mark on the piston head should face the crankcase cover side 2 Install the big end cap Always use a washer for the tightening nuts Apply oil to the crank pin Install the rings in the proper direction Apply oil to the outer surface of the pis ton an
39. 0 800 217 578 15 0 581 300 1600 17 0 669 19088 217 1157 21 0 827 Plastigage To measure clearance between crankpin and main bearing L Tee Applicable clearance mm in Plastigage Green 0025 0076 0 001 0 003 PR 1 Red 0 051 0 152 0 002 0 006 xem PB 1 Gray 0 102 0 229 0 004 0 009 Measuring scale Thickness gauge To measure clearances between piston rings and piston grooves or between shaft couplings during installation Battery electrolyte To inspect antifreeze solution and tester electrolyte for specific gravity and 95000 00013 charging condition Compression gauge 140 1100 To measure compressive pres sure in the cylinder Tool set TOL 97190060 Nozzle tester Pressure gauge 0 500 kg cm inspect spray condition and 737600 93502 the injection pressure of the fuel injection valve High pressure pipe 124233 93400 yaaa Penetrant 450cc 275 Use in detecting n cu in in few detection Benatan en ek Developer 450 cc 27 5 cu in 97550 004520 Set product 6 bottles Cleaning agent 450 cc 27 5 cu in 975500 004560 97550 004530 21 Disassembly and 3 Instruments Select the appropriate thermometer and tachometer from among the following types Instrument
40. 0331206 464 Telefax 40331205 160 YANMAR HEAD OFFICE 1 Chrome 32 Chayamachi Kita ku Osaka Japan Telephone 810 6376 6211 Teleac 81 0 6 6377 1242 YANMAR EUROPE BV POBox 30112 1303 AC Almere NL Brugplein 11 1332 85 Almere De Vaart The Netherlands Telephone 31 36 549 32 00 Telefax 431 36 549 3208
41. 0AE 0 0002 0 0007 4 Piston rings 2nd sing ZA Tapered taco 1 Measuring piston rings Measure the thickness and width of the cnepade piston ring Insert the piston ring into the SS piston ring groove and measure the clear ance Ring configuration Replace the piston ring if it exceeds the service limit Piston ring PI 2nd ing Oi ring T 8 Standard 27 29 1 470 1 485 275 295 1 470 1 490 26 28 3 470 3 490 5 0 01065 01141 00579 00585 01063 0 1161 00579 0 0587 0 1034 0 1102 0 1366 0 1374 Service 252 1 36 275 136 249 336 Dr 0 0992 0 0535 0 1089 0 0535 0 0980 0 1329 30 32 1470 1485 2 1470 1490 20 24 3470 3400 Ub Standard 0 1181 0 1260 00579 00585 0 1181 0 1260 0 6579 0 0887 00787 00945 0 1366 0 1374 Service 277 126 277 126 189 336 fmit 0 1091 0 0535 0 1091 0 0535 0 0783 0 1323 Standard 32 34 1470 1485 32 34 14470 1 490 21 25 3 470 3 490 0 1260 0 1339 0 0579 0 0585 0 1260 0 1339 00579 00587 0 0827 0 0984 0 1366 0 1374 LONE Servis 297 136 297 126 207 336 limit 01169 00535 01169 0 0535 00816 01323 2225 1470485 33 35 1970 1990 2428 3370 3990 inda 0299 0379 00579 00585 0 1300 0 1378 00776 00783 10945 0 1102 0 563 0 1571 Serice 136 307 186 237 386 imi 01209 0 0535 0
42. 1209 00732 0 0029 01520 2426 1470 1485 3436 1970 1990 25 29 3970 3990 0 1339 0 1417 00579 00585 0 1339 0 1417 09776 00789 0 0984 0 1141 01562 01571 Service 317 136 an 19 247 356 imi 0 1248 0 0535 07248 00732 00972 0 1520 Sumus 3538 1970 1990 25 28 3970 3990 LIO0AE tard 0 1417 0 1496 0 0579 0 0585 0 1417 0 1496 0 0776 0 0783 0 0984 0 1141 0 1563 0 1571 Seco 237 126 337 186 247 386 limit 0 1327 0 0535 0 1327 0 0732 0 0972 0 1520 43 Checking and Servicing cing and Servicing Piston ring side clearance mm n Model L40AE 175 Item 170 L100AE Ring width i5 20 Clinder sleeve Bing g 0 0591 0 0787 Cylinder block st 0 Standard 00055 0 does Umit 0 15 0 0059 Ring width 15 20 o Pullout ang Ring groove 0 0591 0 0787 the piston ring 903 0065 iL Side Standard 9 0012 0 0026 NULL Piston ring Glearance mit 0 15 0 0059 yid Push in Measur sing end Ring width 35 40 ng me palon haad Sap by Ring groove 0 1378 0 1575 gauge into it Measuring of ring end ga Standard nA 0 9 9 T 015 00059 Measuring of ring end gap mm in Model LA0AE L100AE Standard Serv
43. 2 Fill up the lubrication oil to the filler port with the engine horizontal 4 Priming with lubricating oil Turn the fiywheel as follows to make sure oil gets to all engine parts 1 Set the speed control handle to the STOP 2 Set the decompression lever to the Non compression position 3 Turn the flywheel Make sure no abnormal sound occurs 6 2 STARTING 1 Set the fuel cock to position O open Fuel cock OPEN This figure shows the operating position Starting 1 2 Set the regulator handle to the START position and tighten the knob The FO limiter must be in the increase position Otherwise the engine may not start F O limiter Regulator handie This figure shows the starting position Starting 2 3 Pull out the recoil starter handle 1 Pull out the recoil starter handle grip slowly until it feels tight to pull then let it back slowly Turn the decompression lever to Non compression by one hand The decompression lever returns auto matically when the recoil starter handle is pulled x Starting 3 2 3 Grip the recoil starter handle with both hands and give a good strong pull Test Run Starting 3 3 4 If it is hard to start the engine in cold weather remove the rubber plug on the valve rocker arm cover Add about 2 cc of lubricating oil to aid starting L40AE LTOAE only not apply this opera tion to L
44. 256 Displacement 1 cuin 0 406 24 78 Continuous 66 9 0 oa Maximum s em 7 4 10 0 Speed PTO shaft 3600 1800 3600 1800 Speed at no load max min mm Lor w Compression ratio 193 PTO position Crank PTO shaft Direction of revolution Counterclockwise viewed from PTO shaft Fuel injection pump Bosch type YANMAR PFE M type Fuel injection timing FID _bTDC 13 Fuel injection nozzle Hole nozzle YANMAR YDLLA P type Fuel Fuel injection pressure 19 6 200 Fuel oil selection Diesel fuel 5 2869 1 or equivalent Fuel oil fiter Paper element FO tank built in type Fuel oil tank capacity US gal 5 5 1 45 spak baton roe ck a amber Lubicating Lubricating fiter Resin 60 mesh oll Lubricating oil selection SAE 10W30 API grade CC or higher Lubricating capacity US gal Air cleaner Wet type paper element fiter Oil bath type Option Exhaust silencer Expansion silencer with cover Governor All speed type mechanical NT sme Dry weight kg b 48 5 106 9 54 0 119 0 Permissible angle of inclination deg 20 momentary 30 Balancer shaft i 2 Single shaft Specifications 1 2 Cross Sectional Views Decompression lever Air cleaner Exhaust valve Flywheel cooling tan Piston Crankcase cover Stiffner bot Recoil stator Lubricating oi fiter S
45. 2651 2856 Crankshaft Ballbearing L amp OAE 79 987 80 000 bearing part L OAE 3 1491 3 1496 175 89985 90000 LHOOAE 35427 35433 L4oAE L48AE L60AE L7OAE 175 LAOAE ES Camshaft bearing part 10 68 16 2 6835 7016 2 7622 75 18 2 9598 77 78 000 78 000 7818 Cylinder sleeve LD 26000 76030 EA 80 000 80 030 2018 175 31496 31509 3 1567 84 000 84 030 84 18 1 0 35071 33083 23142 voae 86000 86030 9618 11 22858 33870 3 3929 16 Service Standards Unit mm in Parts Model Standard Service limit Remarks Oil pump Trochoid pump Outerrotor 140 2896 2898 28 90 I LIO0AE 1 1402 1 1409 1 1378 Housing LD LAOAE 29100 29121 29 18 Outer Crankcase over 100 1 1457 1 1465 1 1468 Clearance bet LAOAE 0 120 0 161 B andouerotr 1100 00047 00063 Outer and inner 140 797 800 790 rotor with LI00AE 03138 03150 05110 140 802 805 8 10 Wah Housing depth 100 0 3157 0 3169 0 3189 Clearance bot weenhousing LAOAE 002 008 andinnerouter 100 00008 00031 rotors Clearance between the inner and outer L4QAE lt 0 4 025 rotor L100AE 0 0055 0 0098 Cylinder compression pressure at 3000 140 2942 kPa 90 kgticm 2452 k
46. 2756 0 2762 7 06 0 2780 Oil clearance 0 020 0 055 0 0008 0 0022 23 972 23 993 0 9438 0 9446 23 89 0 9405 Hole dia Cylinder block 24 000 24 033 0 9449 0 9462 24 06 0 9472 Oil clearance 0 007 0 061 0 0003 0 0024 E 4 6 TIMING GEARS 1 Checking the timing gears 1 Check each gear and replace those that damaged or worn 2 When reassembling line up the timing marks each gear Gear train 52 scking and Servici 4 7 CRANKCASE COVER Always handle the aluminum packing with care When the crankcase cover is disassembled replace the aluminum packing on the crankcase cover if damaged or deformed Be sure to tighten the crankcase cover to the tightening torques as specified below The crankcase cover is held in position by two knock pins Tightening torque kg cm lb ft i dm L40AE L48AE L60AE L100AE Crankcase 100 120 200 230 cover 7 2 8 7 14 5 16 6 Siiffener bolt 200 230 14 5 16 6 1 Cleaning and checking Clean the cylinder block when the engine is overhauled Clean out each oil hole and make sure it is not clogged Leave plugs in place if they do not need to be replaced Protect the plugs from oil leaks Crankcase cover Oil hole and blind cover of the crankcase mm in Model L40AE L48AE L6OAE L70AE L75AE LI00AE Service Service Service hem Standard
47. 28 9 32 5 4 Disassembly and reassembly Remove the case nut and then all parts of the valve can be disassembled To disassemble and reassemble the case nut use a 15 mm deep socket wrench The fuel valve positioning pin does not need to be removed in most cases 5 Adjustment The injection starting pressure is 200 kg To adjust the nozzle injection starting pressure remove the nozzle holder and increase or decrease the number of adjusting shims Adjustment by 0 1 mm results in a change in the injection starting pressure of about 20 kg cm Adjusting shims come in the following thick nesses 0 1 0 15 0 4 0 5 0 6 0 7 and 0 8 mm mm in L40AE L100AE Adjusting shim 0 60 0 65 standard thickness 0 0236 0 0256 61 ZZ Fuel injection valve assembly Checking and Servicing 3 Fuel filter The fuel filer uses an element of nominal filterable particle diameter of 5 During the periodical inspection of this part check the element for break separation from the frame to which it should be bonded stoppage etc and if a defection is found replace it with new one To detach the fuel filter first remove the filter cap on fuel tank then pull out it from the fuel filler port But pull the fiter down wards for YDG generator set YLP and YDP pump set 4 11 SPEED CONTROL DEVICE The position where governor spring must be in stalled differs depending on engine model
48. 449 0 8232 0 9020 3 Checking piston pin hole Piston mm in 1 Replace the piston if the pin hole is Model Standard Service limit discolored or damaged L40AE 67 965 2 6758 67 68 2 6646 2 Measure the 1 0 of the piston pin hole If 148 69 965 2 7545 69 70 2 7441 it exceeds the service limits replace the L60AE 74965 29514 74 70 29410 Piston U70AE 77 965 8 0694 77 70 3 0591 3 Piston replacement procedure 175 79 965 3 1482 79 70 3 1378 Heat the piston to 70 80 158 176 83 965 3 3057 89 70 3 2953 align the small end hole with the piston pin LIPE esse Gesta hole then insert the piston pin into the hole Recommended way ot heating Heat the piston in oil Avoid heating it directly Checking piston pin hole Clearance between Piston and Sleeve mnm in Model Standard Service limit LA0AE 0 04 0 06 190 0 00157 0 00236 0 05 0 07 LI00AE 0 00197 0 00276 Piston pin hole LD mm in Model Standard Service limit 140 18 985 18 996 19 07 148 0 7474 0 7479 0 7508 160 20983 20996 2107 LOAE 08261 08266 0 8295 175 22 983 22 996 23 07 LI00AE 0 9048 0 9054 0 9083 42 Checking and S Clearance between piston pin hole and pin mm Model Standard Service limit 0 004 0 015 0 0002 0 0006 L48AE 0 005 0 017 L10
49. 5 0 92 Typo of ubrcaton Lubricating oil fiter 2 Resin 60 mesh Lubicating 1 oi Lubricating oil selection SAE 10W30 API grade CC or higher Lubricating capacity US gal hih dd 59 Air cleaner Wet type paper element filter Oil bath type Option Exhaust silencer Expansion silencer with cover Governor All speed type mechanical n SEE Ty Dry weight kg lb 335 73 9 39 0 860 33 5 789 39 0 86 0 Permissible angle of inclination deg 20 momentary 30 Balancer shaft Single shaft L75AE L90AE Item D 5 DE S p S be SE Type Single cylinder vertical 4 cycle air cooled diesel Cooling system Forced air cooling by flywheel fan Combustion system Direct injection system Starting system Recoil starter Recoil starter Number of cylinders Bore x Stroke 15605756 3307 2766 Displacement cuin 0 351 21 42 0 887 23 62 Continuous 48 65 5 9 89 Output Maximum PCS 55 cm 66 8 0 Speed PTO shaft 3600 1800 3600 1800 3600 1800 3600 1800 Speed at ric tond Wasi 40 2702 927 222 oo Compression ratio 202 189 PTO position Crank Cam Crank Cam Crank Cam Crank PTO shaft Direction of re
50. 75AE to 100AE Otherwise the recoil requires a stronger pulling force and the engine becomes more difficult to start Since this rubber plug is not necessary for engines for tropical countries a blind plug is provided on those types instead CAUTION Keep the plug in the hole when it is not in use 10 block out water dust etc If the plug is left out rainwater and dirt intrude to cause early wear of engine and other troubles Never add too much oil as starting aid 112 Test Run 6 3 OPERATION 1 Warmup the engine for about 5 minutes 2 When the engine is warm put the speed control handle in the required rpm position and tighten the knob 6 4 STOPPING 1 Turn the speed control handle to the low speed position Run the engine in no load state for about 5 minutes 2 Turn the speed control handle to STOP CAUTION Always allow the engine to cool off before stop ping 8 Return the fuel cock lever to S close 4 Pull out the recoil starter handle slowly then stop pulling when it feels tight 113 Helical inserting Part for Repair 7 Helical Inserting Part for Repair 1 Helical inserting part for repair 1 The helical inserting part for repair is the generic name for the helicel inserting part and its special purpose tool it is a kind of special threaded bushing The helical inserting part is used for repair ing broken bolts and worn out female screw Shape and n
51. 783 LGOAE 21 25 207 Tedimensions 70 00827 00984 0 0815 Oil ring 24 28 237 L75AE 00945 01102 0 0933 L90AE 25 29 247 1 00 00984 01141 0 0972 L40AE 3470 3490 336 L7OAE 01366 01374 0 1229 Beimensions SAE 3970 3990 3 86 LIOOAE 01563 01571 0 1520 P 140 020 035 10 string LIOOAE 0 0078 0 0138 0 0394 5 L40AE 030 045 10 End gap 2nd ing LIOOAE 00118 00177 0 0394 ot LAOAE 015 035 10 fing LIOOAE 0 0059 0 0138 0 0394 Connecting rod Laoag 19 012 19 024 19 10 LABAE 07485 07490 0 7520 L6OAE 21014 21028 21 10 L7OAE 08273 08279 0 8307 175 23025 23038 23 10 Small end hole L100AE 09065 09070 0 9094 piston pin LAOAE 0 015 0 030 148 0 0006 0 0012 gt d L60AE 0017 0034 Otetearance TOME 00007 00013 175 0028 0044 1100 0 0011 0 0017 L40AE 30007 30015 30 09 L4BAE 1 1814 1 1817 1 1846 160 36007 36015 36 09 VY direction L7OAE 14176 14179 1 4209 Large end hole L7SAE 40000 40042 40 08 Crank pin L100AE 15748 15765 1 5780 140 0025 0050 70 10010 00020 dearance us L7SAE 00330062 e L100AE 00013 00024 12 Service Standards lt _ ala q K l x _ Unit mm in Parts Mode Standard Service
52. 901 05906 05870 Beaing 15016 15094 35016 15034 35016 15034 8 1 05912 05919 05912 05019 E 05912 05919 3 oir 0 016 0 045 0 016 0 045 0016 0045 23 clearance 00006 00018 0 0006 0 0018 0 0006 0 0018 Sem 24980 24993 2450 295629555 2950 34 980 94 393 3430 5 0 9835 0 9640 0 9803 1 1803 1 1808 1772 1 3772 1 3777 1 3740 Bearing 26990 25000 2502 259930000 2002 34990 85000 3502 9539 0909 09850 11807 11811 11819 13776 13780 13787 Bs for 0020 0000 9020 0090 9020 0020 clearance 00008 0012 00008 00012 0 0008 0 0012 gt 0 280 045 0040 0280 045 0040 0280 045 Clearance 0 0016 0 0110 00177 00016 00110 00177 00016 00110 00177 51 Checking and Servicing 2 Tappet 1 Check the condition of the tappet contact point The tappet is offset with regard to the cam center and rotated during operation to prevent uneven wear Replace the tappet if it is badly worn or contacts the cam un evenly 2 Check the outer surface of the tappet for wear and damage Replace if defective CAUTION Keep the intake and exhaust tappets separate in disassembling or reassembling them Tappet mm Model L40AE L100AE Standard Service limit Stem 0 0 6 960 6 980 0 2740 0 2748 6 87 0 2705 icon Exhaust Hole dia Cylinder block 7 000 7 015 0
53. BAE 13386 133 Lo 60 39000 99025 E 4 L7OAE 15354 15364 L75AE 44000 44025 E LiO0AE 17323 17333 LAOAE 070 34105 LABAE 13413 13427 Bearing LeoAE 9070 39105 Plein L7OAE 1 5382 1 5396 Crankshaft L7SAE 44085 44 120 m bearing part LIOOAE 17356 17370 LAOAE 0 045 0 105 Tight fit 170 00018 00041 Fitting 175 0060 0120 m 00 0 0024 0 0047 140 30 30 13 LASAE 1 1811 1 1862 metal LEQAE 35 35 13 LD Plain meta L70AE 1 3780 1 3831 175 40 40 13 L100AE 1 5748 1 5800 140 51945 51965 20451 20455 160 6194061960 LD LOAE 24386 24394 175 71935 71955 LIOOAE 28321 28329 140 51987 52000 Tight fit l4BAE 20467 20472 Camshaft Ball bearing LSOAE 61987 62000 beering part OD 170 24404 24409 175 71987 72000 F LIO0AE 28341 28346 L40AE 0 022 0 055 zx L4BAE 00009 00022 L6OAE 0 027 0 060 m 170 00011 00024 175 0 032 0 065 00 0 0013 0 0026 15 Service Standards Unit n Parts Model Standard Service limit Remarks Cylinder block LADAE 71 9905 720095 m L48AE 28343 28350 55 Leak 79960 79996 Fa L7OAE 31488 31494 175 89984 90000 lt 1100 35427 35433 140 71987 72000 L4BAE
54. Bot Tpcs Nu pcs LA0AE L7OAE 26116 3 26716 6 060454 060002 175 110 lal 18 seal fiting tool Acplicable Cylinder block Sidecover Code Crankshaft Crank amp Cam shaft 114250 923171 L40AE L48AE 114350 092311 140 L7OAE LGOAE L70AE 114650 92310 175 1100 Oil seal fitting guide After insertion of seal into crankcase cover use this too to install crankcase cover on cylinder block Jig for inserting crankshaft and camshaft oil seals Code I Applicable Model 14250 92301 L4OAE S LABAE S L40AE D LABAE D 114268 92300 L40AE DE L48AE DE 114350 92301 L60AE S L70AE S 160 L7OAE D 114368 92300 L60AE DE L70AE DE 114650 92300 L75AE S L90AE S _100 5 114668 92300 L75AE DE L90AE DE LT00AE DE Valve stem seal fitting tool Model Code LAOAE L48AE 14250 92350 L60AE L70AE 114350 92350 L75AE 100AE 114650 92350 Dimensions of oil seal fitting tool oil seal fitting guide flywheel tightening handle flywheel extractor and valve stem seal fitting tool are detailed in Appendix 2 19 2 Meters Instruments and Service Accessories Necessary for middle and small size engine service shops Disassembly and Reaseembly Typical sizes Instrument
55. CB Female Receptacle type LA Eyelet type 68 Checking and Servi 2 Starter Motor Type of starter motor Starter motors are roughly divided into the com mon type conventional type and reduction type they are subdivided into the Bendix type and magnetic shift type The clutch is available in the 1 Specifications and Performance roller clutch type and multi plate clutch type depending on pinion engagement mechanisms The L A series uses the common type magnetic shift system starter motor as standard A 140 5 L40AE DE L7SAE SE LIODAE SE Engine model L100AE SE L100AE DE Optional Type Conventional Reduction type Model 5114 414 5114 478 Rating sec 30 e Output V KW 12 08 12 12 Direction of rotation viewed from pinion side Clockwise Counterclockwise Clockwise Weight kg 3 6 7 9 44 9 7 Clutch system Over running lt Engagement system Magnetic shift lt No of pinion teeth 8 Pinion coming out voltage V 8 Terminal voltage V 115 12 _ Current 60 Max 105 Max Speed rpm 7000 Min 4000 Min Loaded Terminal voltage V 8 87 characteristics Current A 200 2 Torque kg m ft Ib 0 32 2 31 1850 rpm 0 46 3 83 1550 rpm Min Min Min Min Characteristics Curve sue oatey NOES ful Sarge 69 Current A C
56. Discrimination 1 Difference in direction of mounting shroud due to the different directions of cooling fan revolution Viewed from the rear side shroud 7 Recoil starter Assembly Discrimination 1 Difference in the direction of mounting the grip 2 Direction of revolution Counterclockwise Viewed from the outside 118 Difference between Parts under Spec S and D No U Parts name Difference Specification 5 Specification D 8 Starting motor EDS 4 Vigroove Pinion 1 Direction of revolution viewed from A side Clockwise Counterclockwise 2 Discrimination V groove at the Absence Presence pinion end 3 Name plate Manufacturer Hitachi Model No 5114 413 5114 414 119 Details of Spec ial Tools Appendix 2 Details of Special Tools Oil seal fitting tool Unit mm n steel Patscode Dimensions free 9 m 70275 14250 02211 16063 16141 24455467 952 17520 1 7598 2 05 49 5 9 49 7 59 m 14650 92310 1 9488 1 9567 229 EE 32 o gt C0 5 C0 02 costco02 NOR 01520162 seal fitting guide Unit mm n Material steel Partscode Scale free n D 5 02
57. LY PROCEDURES Basic procedures 2 Exhaust silencer Gather the required tools jigs and meters 1 Remove the flange nuts e Have a notebook etc ready for recording 2 Remove the stay bolt service information 4 Fill containers with cleaning solution for cleaning parts Prepare a special place for parts and contain ers Drain old lubricating oil from engine Arrange disassembled parts Keep all bolts and nuts with their relative parts 1o make sure they are not reassembled incor rectly Determine exactly what the problem is before disassembly Never remove unnecessary parts Removing the exhaust silencer 3 Air clearner 1 Fuel tank 1 Remove the air cleaner cover 1 Pull the overflow pipe out toward the tank 2 Pull out the filler element 2 Release the hose clamp on the pump side 3 Remove the cleaner case of the fuel pipe 3 Remove the fuel tank stay upper part 4 Remove the fuel tank Pull the oil pipe on the pump side up and Release the hose clamp on the pump side Removing the air cleaner 4 Recoil starter The recoil starter does not have to be removed every time Remove only when necessary 5 Cooling fan case Removing the fuel tank Remove the cooling fan case 25 Starter pulley V Td Removing the cooling fan case 6 Starter pulley Remove the starter pulley 7 Air intake bend Remove the air intake bend Removing the air intake bend
58. Pa 25 rpm engine speed tum the starter motor L100AE 427 ps 56psi Cylinder compression pressure at 500 L40AE 2452 kPa 25 1961 kPa 20 engine speed pull the recoil starter L100AE 356 psi 284 psi 17 3 Disassembly and Reaseembly 3 1 TOOLS METERS AND INSTRUMENTS Disassembly and Reaseembly Keep the following tools jigs and other service items on hand to ensure accurate measurement and diagnosis and efficient servicing 1 Tools Name of tool Description YANMAR Code No Mustration YANMAR service tool set Type A including 65 tools 95500 00001 Type B including 46 tools 955000 00002 Piston inserting tool Commercially available Hexagonal wrench 955500 02476 For 60 125 Bore Pliers 28190 000130 included in YANMAR service tool set Shaft pliers 28190 000020 included in YANMAR service tool set Piston ring remover 135410 92140 Cleaning needle for fuel Wire use 90 19 injection valve Commercially available Pinvise Commercially available 28210 000010 Disassembly and Reaseembly Name of tool Description YANMAR Code No Mostration Flywheel end nut wrench Special purpose tool for tightening the crankshaft end mut 14220 22100 a P ia Flywheel extractor 14250 92121 Model
59. Sspec i L75AE L100AE This completes the disassembly and reassembly For cautions sake be sure to check that all the parts are reassembled correctly according to the following procedures 3 Checks after reassembly 1 Pull out the starter rope a little by pulling the grip 2 or 3 times D When the grip is too heavy to pull check whether the parts are bled correctly O When the ratchet does not move check whether the friction spring is reassem bled 2 Pull out the starter rope for the full stroke with drawing the grip D When the starter rope is left inside the reel or the starter rope will not return at all an undue force is applied to the spring In this case rewind the starter one or two tums according to the procedures under Fig a When the return of the starter rope is weak or the grip hangs down in the midway lubricate the friction parts with several drips of engine oil When the failure can t be corrected still rewind the starter rope one or two tums Check whether an undue force is applied to the spring according to the procedure above When the spring is detached from the reel s hook and the starter rope can t be wound inside the reel follow the reassmbly procedure again 36 Checking and Servicing 4 Checking and Servicing 4 1 CYLINDER HEAD 1 Combustion surfaces Remove the fuel injection valve intake valve and exhaust valve Clean the va
60. Timing mark Fuel injection timing mark for measurement are on the periphery of the flywheel Ring gear has been shrinkage fitted on the flywheel at approx 180 C 356 F Ring gear Chanfering side ga GY OT eu gs m D spec engine S spec engine Checking and Servicing 4 5 CAMSHAFT AND TAPPET 1 Camshaft 1 Checking the clearance at the thrust of the camshaft cylinder block side Check the clearance at the thrust of the camshaft The camshaft bearing has been press fitted into the cylinder block Main ain the sinkage between the pressfitted bearing face and the thrust surface of cyl inder block at 1 4 1 5 mm a 14 15mm 10 0551 0 0787in 2 Measuring the camshaft and bearing Crankcase cover side Measure the 1 0 of the ball bearing and of the camshaft Replace to ball bear ing if it exceeds the wear limit or is badly damaged Overlap 50 40 Exhaust valve closed Intake valve closed Exhaust valve closed sea 594599 Valve timing valve clearance in cold state at 0 15mm Shape of fuel cam Reverse preventive type Cam shaft thrust clearance Camshaft mm n Model LAOAE LABAE L60AE L70AE L75AE LT00AE tom Standard Sevice me Standard iy H 14 999 15 000 3492 14909 15000 1492 14 989 15 000 3492 8 05901 05000 05874 05901 05908 05874 05
61. YANMAR SERVICE MANUAL L40 L100 AIR COOLED LA SERIES INDUSTRIAL DIESEL ENGINES as INTRODUCTION This Service Manual offers instructions on standard service procedures disassembly and reassembly for Yanmar Diesel Engine models L40AE L48AE L60AE L70AE L75AE L90AE and L100AE More detailed information is given particularly in the sections of the construction and function of each engine part Before servicing these engines make sure you read this manual carefully The information contained in this manual will be updated periodically to incorporate improvements in the quality and performance of our engines Before beginning your service work To insure efficient service and repairs the following pre service steps should be taken 1 Check your customer control book 1 When was the engine last serviced 2 What is the engine s service history a How often was the engine serviced after how many months or hours of operation b What problems has the engine had in the past 2 Stock control spare parts 1 Keep a good stock of engine parts and other items necessary for efficient servicing 2 Keep a of the check service parts list and plenty of parts cards on hand 3 Keep an accurate service record diary notes etc 1 Work manpower table 2 Check list including service parts list 3 Parts measurement data Maintenance of performance 4 Operation data and quality 4 Tools and eq
62. agnetic switch and shift lever assembly to the gear case Fix the magnetic switch with M6 lock bolts Be sure to install the dust cover before assembling the gear case Tightning torque 65 80 kg cm 4 71 5 80 Ib tt After reassembly check by conducting no load operation 7 Characteristics test The some characteristics can be checked easily by the no load test procedure described below The test should be carried out immediately because the rating of the starter motor is 30 seconds 1 No load test Fix a starter motor on a test bench Con nect wiring to the motor as illustrated Close the switch and current flows through the motor which is rotated at no load Measure working current voltage and motor revolu tions Check whether the specified charac teristics are satisfied 82 Checking and Servicing 8 Maintenance Standards Measuring position item Unit 5114 413 414 5114 478 Standard spring load kg b 1 8 2 2 377 485 Brush Standard height mm n 14 051 16 0 630 Wear mit n 11 0 433 Magnetic Series coil resistance 0 33 Shunt coil resistance 1 13 06 Outside diameter Standard 33 1 299 30 1 181 Wear limit 32 1 260 29 1 142 Commuta off set Standard 0 05 0 002 0 03 0 0012 tor Repair limit n 0 4 0 015 0 2 0 008 Mica depth Standard mm n
63. all the element 3 Install the cover Make sure the intake bend and packings in position Paper element Air cleaner Packing intake bend Packing Intake bend lt Intake bend 9 Element Lower Rough density L60 Oii pan Oil level line bath type air cleaner b Intake bend 17 Starting motor Only for model with starting motor Install the starting motor 33 18 Exhaust silencer Install the exhaust silencer e The silencer cover does not have to be removed Model L75AE L100AE have not a rear Exhaust silencer 19 Fuel tank 1 Connect the fuel pipe to the fuel injection pump 2 Attach the fuel tank using the upper stay 3 Insert the fuel return pipe to the fuel tank Make sure the fuel tank supporting rubber vibration absorbing rubber stays in place Installing the fuel tank 3 6 RECOIL STARTER The recoil starter will not be trouble in normal usage However should it break or when it must be lubricated disassemble and reassemble it according to the following procedures Tools used box wrench pliers screw driver 1 Disassembling procedures 1 Remove the recoil starter from the engine Use box wrench 2 Pull out the grip and draw out the starter Tope for approx 30 cm When the reel s notch came at the outlet of the starter rope fasten the reel s tuming by your thumb and draw up the starter rope inside the recoil
64. alues in the table were obtained in the nor mal condition Note that this simplified in RS5112 spection is not intended to detect all failures and troubli Notes Use a tester at a range of 10 ON The pointer moves OFF The pointer does not move 2 Be sure to inspect a desired regulator while checking it agaunst a normal one 1 Tester Red lead wire 5 Termine 5 lo 117 xb 1 2 OFF 3 OFF 4 OFF 5 OFF z 6 ON 7 OFF 8 OFF 9 10 OFF 3 5 pn on 2 OFF 14 OFF 15 OFF 2 4 16 OFF 17 OFF 18 OFF 19 OFF 20 OFF 5 21 22 ON 23 ON 24 OFF 25 ON LE Case 26 OFF 27 OFF 28 OFF 29 OFF 30 OFF le in the regulator Regulator Symptom Faulty point No Probable cause The charge lamp does not turn off 24 ON The harness between the charge lamp and terminal No 4 of the regulator is likely to interfere with the body 5 OFF 26 ON The battery is likely to be connected in reverse The fusible link is fused 5 26 ON The regulator is likely to be poorly insulated within it or BON 26 the battery is likely to be connected in reverse The battery is insufficiently charged off In the regulator the circuit is likely to be opened because or the charge lamp does of poor soldering off d The battery is insufficiently char
65. ame The helical inserting part has a shape like a spring It is made of a wire rod with rhombic cross section as illustrated 4 Use Use the helical inserting part as illustarted 2 3 2 Tap hole D Inserting part male thread 2 Size of helical inserting part 5 The helical inserting part should usually have a length equal to or greater than the thread length of the bolt Notch Tongue Helical Inserting part Table 1 shows a part of standard metric threads Other small threads frequently used include the standard thread 5 0 9 fine threads M12 P1 25 and M12 P1 5 etc Fig 1 shows the size relationship between the helical inserting part and the thread Fig 1 Dimensions for Helical Inserting part 114 Helical Inserting Part for Repair mm in Standard thread Helical insert tapping Helical insert thread Nominal length LB Efecive Bottom Guide Bonom Helicalinsert Etectve iThreed sie da da de 5 FeeoDio _ da 0 MES S350 6000 63 7300 798 747 5350 600 900 1200 j 0211 0296 0248 0287 0314 0299 0211 0236 0354 0472 7188 800 1028 975 7388 800 120 1600 0283 0315 033 0379 0405 0383 0283 0315 047 0630 9026 10000 105 1194 1269 1207 9028 1000 1500 2000 0955 0394 413 0470 0497 0475 0355 0394 059 0787
66. and its rated rpm as shows in the following table and illustrated Check the spring for position before ascertain ing the fuel injection limit Position of Governor Spring Hole Model and Location of governor spring installation hole Application L40AE L70AE T L75AE LI00AE 3600 rpm 3000 rpm 3600 rpm 3000 rpm Type of speed control device 60 Hz 50Hz 60Hz 50 Hz Speed variable regulator handle revolution fixed type remote controllable B Remote control type C Speed variable friction plate type 1 b 1 1 b D Constant revolution lock lever type 1 b 2 1 b Checking and Servi Type A Type B Checking and Servicing 4 12 ELECTRICAL SYSTEM 1 Wiring Diagrams 1 40 L100AE ENGINES WIRING DIAGRAM For 12V 15A 12V 3A Charging Generator Starter motor Lame lator Je n v a ow W Wwe TAM G W Green White Terminal CA Male CB Female Receptacle type LA Eyelet type Grass 5 33A06 ilg ao n asterisk nats a traction aries 1000rpm warm State ambient temperature 20 at 12V at 13V HE R 5iA Leeg Combination of RS5112 55112 regulator Model M Sung metr
67. anel A timer is used for the pre heating When the air heater key switch is turned on the pilot lamp lights The timer is set so that the pilot lamp goes off 15 sec after the system is turned on When the pilot lamp goes off once turn the key switch off Then turn the key switch to the START position to start the engine An air heater system circuit consists of an air heater pilot lamp and timer 306 4 173 7843 071 60 2 362 mm tin M6 terminal 4 99 0 354 Rated output 400W Rated current 33 34 Rated voltage DC 12V Rated operating Pre heating 15 sec time Engine operation 30 sec max Engine stop 30 Range of operating 30 C 22 F or higher temperature Earth polarity Negative earth Body earth 89 78 3 071 Air heater system circuit without timer Main switch Battery Air heater Air heater circuit with timer Air heater Pro hoat 5 The battery is used to start the engine or to bear lamp load and must be well charged Do not use a poorly charged battery which may be unable to attain the motor revolutions required to start the engine at low temperature 1 Battery capacity and battery cables 1 Battery capacity Recommended battery capacity 20 hrs rating Ambient temperature
68. coil starter Recoil starter sieving moror Number of cylinders Bore x Stroke n pm 165 Displacement 4 cu in 0 199 12 14 0 211 12 88 Continuous 28 3 8 42 one Maximum beat 42 35 4 7 Speed PTO shaft rpm 3600 1800 3600 1800 3600 1800 3600 1800 Speed at no load max min Osea zzz Compression ratio 200 199 PTO position Crank Cam Crank Cam Cam Crank PTO shatt Direction of revolution Counterclockwise viewed from PTO shaft Fuel injection pump Bosch type YANMAR PFE M type Fuel injection timing FID bTOC Fuel injection nozzle Hole nozzle YANMAR YDLLA P type Fuel injection pressure Moa bcm 19 6 200 z Fuel oil selection Diesel fuel BS 2869 A1 or equivalent Fuel oil fiter Paper element FO tank built in type Fuel oil tank capacity US gal 2 5 0 66 Lubicating Lubricating fiter __ Resin 60 mesh Lubricating selection SAE 10W30 API grade CC or higher Lubricating capacity 405 gal md 2 Air cleaner Wet type paper element filter Oil bath type Option Exhaust silencer Expansion silencer with cover Governor All speed type mechanical Engine dimensions Length x Width x Height mm in D spec 39x 3418 13071 x 15 118 x 16 378 S spec 324 x 384 x 416 12 756 x 15 118 x 16 378 Dry weight ko ib 255 66 2 31 0 683 255 562 31 0
69. ction valve be sure to check engine model against the identity marks shown above Any injection valve is least identifiable in appearance 2 When removing the fuel injection valve wrap it in cloth to protect the nozzle tip injection port Do not place the nozzle tip directly on the ground Carbon deposits build up on the nozzle in the form of flowers Flowering lowers combustion performance significantly sure the nozzle is free from tamination 2 Shape of injection spray Move the lever of the nozzle tester at a speed of approx 1 2 time sec to check the spray pattern 1 The spray should all be at the same angle from all four injection ports 2 The spray should be a fine mist 3 The spray should be smooth and steady without deviations 4 nozzles 3 Cautions when installing fuel injection valve 1 Tighten the fuel injection valve assembly to the specified torque 2 Clean the sleeve surface Be sure to re place the nozzle gasket at the same time Note If nozzle gasket stays in cylinder head after injection valve assembly has been removed from cylinder head screw M8 or M9 stud bolt more than 100 mm long in nozzle gasket then pull out stud bolts to remove gasket Nozzle spacer Nozzle gasket Fuel injection nozzle Tightening torque 0 8 L40AE L100AE Installing fuel injection valve 100 120 nut 72 87 Fuel injection nozzle case 400 450 nut
70. d the inner surface of the sleeve 4 Make sure the main bearing is in the proper position Check Whether the rod bolts retainer is in position Connecting Rod Tightening Torque _ kg cm lb ft 180 210 13 0 15 2 L75AE L100AE 375 425 27 1 30 7 Installing the connecting rod big end cap 5 Camshaft Balancer shaft 1 Insert the tappets 2 Insert the camshaft 3 Insert the balancer shaft Inserting the balancer shaft Disassembly and Reaseembly Do not confuse exhaust and intake tap pets e Make sure the gears matching marks lined up 6 Fuel injection pump reassembly Temporarily fix in proper position Line up the injection volume marks marking off and attach the control lever to the gover nor lever fork Reassembly the fuel injection pump with a nut for positioning purposes only e Make sure the adjusting shims are used correctly hb Installing the fuel injection pump 7 Crankcase cover 1 Place an aluminum packing between the surface of the crankcase and the crankcase cover 2 Reassemble the crankcase cover Tighten bolts in the sequence shown in the below figure Tighten bolts diagonally 4 protect the oil seal attach the jig for inserting the oil seal to the shaft prior to insertion Apply grease to the lips of the oil seal lt Apply oil to the crank and camshafts e Make sure that the oil pump drive gears are prop
71. e wire of the battery to the S terminal and the wire to the starter motor When attracting the plunger and pushing out the pinion with the shift lever push or draw the pinion by finger in the arrow direction Make sure the pinion does not chatter before the measurement Swich 3 Plunger movement Applicable also to the reduction type Adjustment the stroke of magnetic plunger to the prescribed value Adjust the di mension installing shim adjusting plate on the magnetic switch board There are two types of shim 0 5 mm 0 0197 in and 0 8 mm 0 0315 in in thickness 4 Mesh clearance Applicable also to the reduction type Mesh clearance is the distance between the flywheel ring gear and starter motor pinion in the rest position This clearance must be 3 mm 0 1181 in to 5 mm 0 1969 in 3 5 mm 0 118 0 1976 6 Reassembly precautions When reassembling the starter motor in the reverse order of diassembly paying a special attention to the following points 1 Where to grease e Gears in the gear case e Operating part of the shift lever e Sliding part of the pinion e Plunger sliding part of the magnetic switch 2 Torsion spring and shift lever Hook the torsion spring into the hole in the magnetic switch and insert the shift lever into the notch in the plunger of the magnetic switch through the torsion spring Cher 3 Mounting the magnetic switch Attach the m
72. e end of crankcase Insert camshaft seal into crankcase cover flush with the end of crankcase When insert ing crankshaft oil seal into cylinder block insert it flush with the end of cylinder block Camshaft seat End of cylinder block End of crankcase cover Crankshaft seal Crankshaft Crank shaft oil seal 4 8 CYLINDER SLEEVE AND CYLINDER BLOCK 1 Clinder sleeve The cylinder sleeve FC25S is cast in the aluminum die casting cylinder block Measure the 10 of the cylinder sleeve Re bore the cylinder sleeve if it exceeds the allowable limit and use with an oversized piston mm in 0 25 0 0098 0 50 0 0197 Oversize piston Cylinder block and cylinder sleeve 2 Cylinder block mm in Model L40AE 148 L60AE L70AE L75AE L100AE Service Service Service Item Standard Cima Standard limit limit 1 71 9905 72 0095 79 980 79 996 89 984 90 000 Crank 2 8343 2 8350 3 1488 3 1494 3 5427 3 5433 shaft Ball bearing 71 987 72 000 79 987 80 000 89 985 90 000 bearing OD 2 8341 2 8346 3 1491 3 1496 3 5427 3 5433 Part Fitting 0 0225 0 0095 0 009 0 020 0 015 0 016 0 00089 0 00037 _ _ 0 00035 0 00079 0 00059 0 00063 Camshaft bearing 20 957 20 978 20 957 20 978 20 957 20 978 part I D 0 8251 0 8259 0 8251 0 8259 0 8251 0 8259
73. ectional Views P Service standard Disassembly Reassembly 3 1 Tools Meters and Instruments 1 2 Meters Instruments and Service Accessories 3 Instruments 32 Tightening Torque 3 3 Maintenace Schedule 24 34 Disassembly Procedures 25 3 5 Reasembly Procedures 29 3 6 Recoil Starter gt Checking and Servicing 4 1 Cylinder Head 4 2 Piston and Piston Pin 43 Connecting Rod 44 Crankshaft Flywheel and Main Bearing 45 Camshaft and Tappet 46 Timing Gear 47 Crankcase Cover 4 8 Cylinder Sleeve and Cylinder Block 55 4 9 Lubrication System 56 4 10 Fuel System 58 4 11 Speed Control Device 62 4 12 Electrical System Wiring Diagram Starter Motor Generator Dynamo Regulator and Rectifier Air Heater Battery 4 13 Adjustment 5 Toroubleshooting 6 Test Run 7 Helical Inserting Part for Appendix 1 Difference Between Parts under Spec S and D Appendix 2 Detail of Special Tools Specifications 1 Specifications 1 1 Specifications Model L40AE L4BAE Item D S DE SE 015 DE SE Type Single cylinder vertical 4 cycle air cooled diesel Cooling system Forced air cooling by flywheel fan Combustion system Direct injection system Starting system Re
74. erly engaged 30 sembly and Reaseembly Attaching the crankease cover and tightening three orders Case Cover Tightening Torque lb ft LAOAE L48AE 100 120 7 2 8 7 L60AE LI00AE 200 230 14 5 16 6 3 Stiffener bolts have been added on the crankcase cover to reduce vibration and noise For an engine with stiffener bolts tighten them after the bolts on the periph ery of the crankcase cover are tightened Stitfener Bolts Tightening Torque LA0AE L100AE kg cm lb ft 200 230 14 5 16 6 8 Fuel injection pump reassembly final Tighten the fuel injection pump 4 See page 58 Fuel Injection Volume limi tation Fuel Injection Pump Tightening Torque kg cm lb ft 140 1 100 100 120 72 87 9 Cylinder head 1 Place a gasket packing on the cylinder block 2 Attach an O ring 3 Reassemble the cylinder head e Make sure that the nozzle insulation 31 packing and spacer are in position 4 Before reassembling the valve spring place its identification mark white paint toward the cylinder head 175 L100AE Tightening the bolts of the cylinder head Tighten separatery with two times Cylinder Head Tightening Torque kg cm lb ft Final First Model L4OAE L48AE 150 10 8 280 320 20 2 23 1 L6OAE L7OAE 220 15 9 420 460 30 4 33 3 L75AE L100AE 300 21 7 540 580 39 0 41 9 10 Pus
75. ers are supposed to place an order for parts specifying the parts code listed in the parts catalog Take care not to assemble an improper parts on the engine Some parts available from the catalog are almost or totally the same in shape or profile and yet quite ditferent in their functions The differences between the S spec and D spec parts are detailed below No T Parts name Difference Specification 5 1 Crank case cover 1 P T O shaft hole Discrimination P T O shaft hole Camshaft passes through the Crankshaft passes through the Specification D _ hole hole 2 Direction of LO pump Clock wise Counterclock wise eccentric part 2 Camshaft assy 1 Presence or absence of P T O shaft Discrimination P T O shaft Presence Absence 2 Difference in FO cam Difference in the direction of revolution phase with the same profile 3 Crankshaft cover 1 Presence or absence of P T O shaft Discrimination P T O shaft 5 Presence 117 tween Parts under Spec S and D No Parts name Difference Specification S Specification D 4 Flywheel 1 Embossed mark Discrimination 2 Difference in the direction of bent vane Embossed mark AN 027 5 Piston 1 Difference in the offset direction Discrimination 2 Mark oj H Y 7 6 Cooling fan case
76. eshooting Black exhaust 2 Crank pin bearing metal seizure 8 Crank bearing metal seizure Main causes Remedies Special Instructions D Abnormal operating conditions 1 Operated at overload 1 Reduce load 1 Working procedure 2 Belt too tight 2 Adjust belt tension 2 Procedure for adjusting belt tension 8 Improper pulley diameter 3 Replace puliey 8 Selection of pulleys Power drops See 5 5 Seizure of moving part 1 Piston cylinder liner seizure 1 Repair or replace pistonicylinder 1 Cleaning of cooling air passage diner Handling of lubricating oil 2 Replace the metal 3 Replace the metal 2 Handling of lubricating oil 3 Same as above Low fuel oil quality Change tuet Use of specified fuel Injection timing too slow Adjust by reducing adjusting shims Adjustment of injection timing Poor fuel injection performance Straight shape 1 Nozzle sticking 2 Wornidamaged nozzle valve seat 3 Injectionpressure too low 4 Clogged injection hole 1 Grind or replace nozzle 2 Same as above Adjust injection pressure Wash hole or replace nozzle 1 Handling of fuel 2 Same as above 3 Adjustment of injection pressure Clogged air cleaner element Replace air cleaner element Periodically check and replace air cleaner B Bluish white exhaust Main causes Remedies Special instructions
77. fall down when pulling out the camshaft and may be confused Removing the camshaft Disassembly and Reaseembly 17 Balancer shaft Pull out the balancer shaft Removing the flywheel 20 Crankshaft Removing the balancer shaft 1 Remove the flywheel key 2 Remove the bearing holder 18 Piston and connecting rod assembly 3 Pull out the crankshaft 1 Remove the connecting rod tightening nuts 2 Remove the big end cap 3 Move the crankshaft to the top of the stroke and pull out the piston Remove carbon deposited on the upper inside surface of the sleeve when ex tracting the piston Make sure the main bearing is in the proper position Removing the rod bolts and nuts 19 Flywheel Pulling out the crankshaft 1 Loosen the lock nut 2 Remove the flywheel Use flywheel extractor special tool Securely thread in the extractor bolts Disassembly and Reaseembly 21 Governor or speed control device Remove the governor or speed control de vice if necessary 3 5 REASSEMBLY PROCEDURES Before reassembly e Throughly clean and check parts lt Apply new engine to the sliding and rotat ing parts Use new packings and O rings Use liquid packing agents to prevent oil leakage Make sure the clearance between parts for thrust etc is correct When reassembling line up matching marks on parts Use the proper bolts nuts and washer Tighten the major bolts and nuts
78. g which generates hydrogen Charge the battery in a well ventilated place OTHERS Wear safety shoes working clothes etc before servicing the engine Do not service the engine under the influence of alcohol Keep children and pets away from the engine in operation e Do not have access to rotary part during operation which is extremely dangerous 2 3 ooo m x SERIAL NUMBER LOCATION Engine serial number E is indicated in the engine nameplate and is stamped on the crankcase cover Before ordering service parts be sure to check serial number and identify necessary parts by nos Parts may not have interchangeability as a result of a change in the specification Es in the nameplate SERVICE RULES Use genuine YANMAR parts Parts that do not meet YANMAR s design specification may damage the engine In disassembling the engine in trouble exactly locate the cause of trouble Remove or disassemble only the parts specified in the troubleshooting procedure Use the special tools designed for this engine Install new gasket O ring cotter pins etc when reassembling When torquing bolts or nuts tighten them to the specified torque diagonally Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly After reassembly check all parts for proper installation and operation CONTENTS 1 Specifications 1 1 Specifications 1 2 Cross S
79. g them 28 and Reaseembly lt lt 3 3 MAINTENANCE SCHEDULE Periodical maintenance is key to a smooth running long lasting engine The table below shows when checks should be carried out Check Add Replace Operating hours Every Every Every Every item 20 50 0 200hrs 5008 1000 hrs Check and retighten al bolts Hid bok and nuts a Check and add engine oil 059 2nd and subsequent Check and add fuel oi I I T Replace as Clean and replace oi fiter requierd Air cleaner T Paper In dusty conditions the element should be replaced more frequently every 500 hours element Type replace Clan tuel fter ee Check for leakage engine fuel Check injection nozzle o Check injection pump o Adjust valve clearance 199 intake and exhaust valves o Inspection and refacing of intake and exhaust valve seats Replace piston ring e Check the surfaces of brush for YDG and slip ring generator Check battery Check the battery once a month and add electrolyte if necessary Drain fuel from tank Monthly Replace it Check fuel piping necessary Clean spark arrester option 24 Disassembly and Reaseembly 3 4 DISASSEMB
80. ged or the charge lamp turns off at 6 0r 11 OFF higher revolutions of the engine In the regulator the circuit is likely to be opened because of poor soldering The battery is insufficiently charged or the charge lamp does notturn 10 or 15 ON The battery is likely to be connected in reverse Note Terminal Nos are the same as those listed above RS2190 Tester Red lead wire s l NTeminar I Hos 2 3 4 5 inal No 1 ON OFF 2 OFF OFF OFF ON 3 OFF OFF OFF ON 4 OFF OFF OFF 5 OFF OFF OFF OFF 9 Inspection of rectifier 1 282117 Hall wave rectifier N rminal tise I Female Male Female e Replace the Red Blac No rectifier if the Tester left require Black Yes ments are not met Tester 2 ZR2120 Full and half wave rectifier Female spigot Terminal Diode Diode B DiodeC DiodeD Continuity olojo Normal No hd n va meet not met Checking and Servi Heater Optional n air heater is available for warming intake air during starting in cold weather The air heater is mounted on the end of the intake bend The device is operated by the key switch on the instrument p
81. h rods Insert the push rods lt Ascertain that the tappets are properly in serted 11 Valve rocker arm assembly 1 Reassemble the valve rocker arm assem bly 2 Adjust the valve clearance In Ex valve head clearance 0 15 mm 0 006 in cold state Be careful not to lose or damage the knock pin Valve Rocker Arm Tightening Torque Ib ft LA0AE L7OAE 200 230 14 5 16 6 L7SAE L100AE 430 470 31 1 34 0 Nozzle gasket Install the fuel injection valve Fuel Injection Valve Tightening Torque kg cm lb ft L40AE L100AE 100 120 7 2 8 7 14 Intake bend Install the intake bend Make sure the intake bend packing is in position Tightening the valve rocker arm 15 Cooling fan case 12 Valve rocker arm cover Install the valve rocker arm cover 1 natal he startar puey Make sure the packing is in position 2 Install the cooling fan case Re attach the recoil if it has been re 13 Fuel injection valve moved 1 Insert the fuel injection valve e Attach the seal rubber to the case 2 Install the injection pipe Make sure the collar and fancase sup porting rubber are in the proper position Cheek injection timing See page 60 3 Tighten the injection valve Make sure the fuel injection valve faces to the proper direction Replace the nozzle gasket 32 Disassembly and Reaseembly 16 Air cleaner 1 Attach the air cleaner case 2 Inst
82. h white smoke As the engine reaches normal operating tem perature the exhaust becomes clear or light blue provided there are no problems But if the exhaust does not clear up a problem is indicated and the color of the exhaust gives good idea of where the trouble is When the exhaust color is abnormal turn off the engine locate the problem and take the appropriate action Use the following to help you Clear or light bluish k Normal operating condition Overloading Continuous black smoke Seizure of moving part Incorrect combustion Continuous bluish white smoke lubricating oil is being combusted Causes of abnormal exhaust color are Reducing the load improves the color Black smoke Black smoke continues after load is reduced Abnormal exhaust Uneven rotation Rotation is Bluish white even but smoke splashes from exhaust hole or fuel consumption increases suddenly 109 Excess load Drop in power Seizure of moving part Improper fuel oil Incorrect injection timing Poor injection performance Clogged air cleaner Poor fuel quality Incorrect injection timing Too much in air cleaner for oil bath system much in crank case oil pan Lubricating viscosity too low Bad contact wear or damage of piston ring Worn piston and cylinder liner Incorrect suction valve stem seal Troubl
83. hecking and Servicing 2 Construction The starter motor is composed of three major parts as follows 1 Magnetic switch Moves plunger to engage and disengage pinion and through the engagement lever opens and closes the main contact moving contact to start and stop the starter motor 2 Motor A continuous current series motor which generates rotational drive power 2 1 Conventional type starter motor Standard electric starter Magnetic switch Field coi Brush Brush holder Rear cover bearing metal Thrust washer Through bolt Rear cover 3 Pinion Transfers driving power from motor to ring gear An over running clutch is employed to prevent damage if the engine runs too fast The overrun clutch is composed of the roller and clutch outer as illustrated below The roller is held down the roller in tapered part The overrun clutch is composed of the roller and clutch outer as illustrated below The roller is kept pressed by the roller spring The clutch outer houses the roller in tapered Torsion spring MES Shift lever Over running clutch Goar case Pinion stopper Gear case bearing Pinion Armature Roller spring 70 Checking and Servicing 22 Reduction type staretr motor Option for L75AE SE L100AE SE Dust cover Yoke Rear cover Through bolt Packing 1 Construction of the reduction type 71 starter motor Thi
84. hown in the table tension is correct Apply 1 5 x W to a new belt first installed Belt tension too high gt Adjust belt tension How to obtain proper tension See above Clutch remains engaged P Lubricating oil Shift clutch to proper position disengage viscosity too high Deteriorated Change the oil Use the proper lubricating oil Circa ot Gne eo Incorrect Tighten to specified tightening Check the amount of crankshaft Replace side cover gasket Insert main bearing completely tightening torque L Tghtening torque Seizing gt bearing Main bearing Small crankshaft end gap gt crankshaft end gap Lend gap Seizing Replace bearing Seizing of piston cylinder sleeve gt f Replace affected parts Troubleshooting 4 Failure of starter motor starter battery terminal with ring gear sliding resistance 1 Loosened or corroded Reconnect battery terminal Repair cor 2 Discharged battery amp a Charge battery or replace For improperly 3 Malfunction of or improper gt Check key switch and replace if wiring to key switch 4 Malfunction of starter relay gt Check key switch and replace if neces 5
85. ice limit 0 20 0 35 Measuring the clearance between the piston ring and groove Side clearance 2 Measuring piston ring end gap Measure the ring end gap by using a new cylinder which is free from wear If meas uring the clearance in an engine which is in use measure at the lower part of the cyl inder as this will be most free from wear Push the ring into the cylinder with the piston top ng 0 0078 0 0138 Piston 030045 10 ring ing end gap 779 0 0118 0 0177 0 0394 0 15 0 35 ring 0 0059 0 0138 3 Cautions when replacing piston rings 1 Use the special purpose tool to attach or remove the piston ring Never stretch the piston ring 2 Carefully clean the ring groove The end gap of the top ring should face the in take side 3 When inserting the ring the maker should face up Checking and Servicing 4 Make sure the ring moves smoothly 5 When inserting the coil expander into the oil ring make sure the coil expander joint is opposite to the ring end gap 6 Make sure each piston ring gap is 120 apart 2nd compression ring 4 3 CONNECTING ROD 1 Checking the connecting rod 1 Parallelism or distortion of the large and small end holes Pass the measuring jigs through the large and small end holes of the connecting rod to measure parallelism or distortion Replace the rod if it is bent beyond the all
86. imi Standard limit Standard limit 12 34 000 34 025 39 000 39 025 44 000 44 025 1 3386 1 3396 1 5354 1 5364 1 7323 1 7333 E Bearing 0 0 34 070 34 105 39 070 39 105 44 085 44 120 E Plain 1 3413 1 3427 1 5382 1 5396 17356 17370 8 Fitting 0 045 0 105 0045 0105 0060 0120 _ g 0 0018 0 0041 0 0018 0 0041 0 0024 0 0047 Bearing metal 1 0 30 30 13 35 35 13 40 40 13 Plain metal 1 1811 1 1862 1 3780 1 3831 1 5748 1 5800 LD 51 945 51 965 61 940 61 960 71 935 71 955 lt i 2 0451 2 0455 2 4386 2 4394 2 8321 2 8329 g Ball bearing 51 987 52 000 61 987 62 000 71 987 72 000 ES OD 2 0467 2 0472 2 4404 2 44090 2 8341 2 8346 93 Fitting 0 022 0 055 0 027 0 060 0 032 0 065 0 0009 0 0022 0 0011 0 0024 0 0013 0 0026 Checking and Servicing The S specification differs from the D specification in the direction in which the Lub oil filer is ex tracted for the purpose of facilitating maintenance of the crank case cover mm S specification D specification LO flow path be Van a ural cone Checking and Servicing 2 Replacing the crankshaft oil seal and camshaft oil seal When replacing oil seal use special tool Insert crankshaft oil seal into cranklcase cover untill it is 4 mm 0 1575 in deep from th
87. it 5 58 0 2197 5 40 0 2126 5 960 5 975 5 945 5 960 160 Standard 6 0 6 015 0 2362 0 2368 02346 02352 02341 02346 LTOAE Service limit 6 08 0 2394 5 90 0 2323 L7SAE 6 960 6 975 6 945 6 960 SAE Standard 7 0 7 015 0 2756 0 2762 0 2740 0 2745 0 2734 0 2740 LIOOAE Service limit 7 08 0 2787 6 90 0 2717 CAUTION 1 The intake exhaust valve guides are provided with a valve stem seal Stem seals cannot Distance from head excluding a washer be reused and must be replaced with new ones When inserting the intake and exhaust valve apply lub oil to valve stem Valve guide hi 140 148 9 5 mm 3740 in L60AE L7OAE 8 5 mm 0 3346 in L75AE L100AE 13 5 mm 0 5315 Valve stem seal 38 Checking and Servicing 4 Valve spring 1 2 3 4 Check the valve spring for flaw and corro sion Measure the free length Measure the spring inclination how far the spring inclines to the left or right Measure the spring tension on a spring tension tester es B LIAE d 10 mark white painted Valve spring e Precaution for assembling the valve spring Applicable to L75AE to L100AE Place the identification mark white painted of the valve spring toward the cylinder head 5 Measuring the top clearance 1 Remove the cylinder head Place high qual ity fuses 01 2 x about 10 mm 0 39 inch at three points on the up
88. it Remarks Valve opening closing timing 140 E LIAE Li00AE 20 b The Intake 140 se aBpc Closed L7SAE Denk SraBDC 140 one SBD 175 53 b B DC Exhaust EAE E 25 a T D 0 Closed 175 satoo Piston 140 67 965 2 6758 67 68 2 6646 position 148 69 965 2 7545 69 70 2 7441 0 50 mm iS0AE 74 965 2 9514 74 70 29410 Piston 0 0 L70AE 79 965 3 1482 77 10 3 0590 L7SAE 7 9965 3 1482 79 70 3 1378 L90AE 83965 3 3057 83 70 32953 LIAE 85969 0384 85 70 3 3740 L40AE 004 006 m Clearance between piston and i90AE 00157 00236 sleeve 0 05 0 07 LE 0 00197 0 00276 140 7 18985 189 6 1907 148 07474 07479 0 7508 Piston pin hole ID LGOAE 20 983 20 996 2107 L7OAE 08261 08266 0 8295 175 22983 22296 2307 LIO0AE 09048 09054 0 9063 Laoag L0004 0015 T L Loose fit Clearance between piston pin hole 0 0002 0 0006 T Tight fit and piston pin I 148 10005 0017 1100 00002 00007 10 Service Standards Unit mm in Paris Mode Standard Service limit Remarks Piston pin 140 18992 19000 1892 148 07477 07480 0 7449 TM 180 20991 21000 2091 Piston pin O D L7OAE 0 8264 08260 0 8232 175
89. jected If it is not turn the flywheel once Turn the flywheel slowly untill fuel flows out of the pipe When the fuel begins to flow check the angle using the mark on the flywheel Repeat three or four times to make sure the reading is correct TD position mark Measurement pipe 2 How to adjust the injection timing e Remove the fuel injection pump and base 4 Add or remove adjusting shims If the timing is fast add shims If the timing is slow remove shims Each 0 1 mm 0 0039 in changes the timing by 1 degree FID L4OAE L7OAE L75AE L100AE Injection timing FID bTDC 13 15 12 14 deg 2 Bleeding air from fuel system Air can enter the fuel oil pipe system when the engine is first installed the fuel oil pipe is removed etc Bleed the air according to the following instructions 1 Place the speed contro handle in the run position 2 Open all cocks of the fuel system 3 Set the decompression lever to the position Non compression 4 Make sure that fuel comes out from the fuel injection nozzle while pulling the recoil starter it can be heard injection sound Loosen the delivery valve holder to bleed the air easily Retighten it to 300 350 kg 21 7 25 3 Ib ft with a torque wrench Checking and ing 3 Fuel injection volume limitation 1 Adjustment before shipment The control lever the spring sheet to line up with the edge is fixed after the rated revo
90. limit Remarks Crankshaft and Main bearing L40AE 29 965 29 982 2990 L4SAE 1 1797 1 1804 1 1772 Pin OD 160 35965 35982 35 90 LJOAE 14159 14166 1 4434 Crank pin LISAE 39965 39982 39 90 LTODAE 15734 15741 1 5709 0095 0055 0010 04 Oi de 0 0010 0 0022 1 5 0033 0062 LIOAE 00013 00024 L40AE 30002 30015 2991 L4BAE 1 1812 1 1817 1 1776 160 35002 35018 2491 Joumal O D C70AE 13780 13787 1 3744 Gear cover 175 40002 40018 3991 side LI00AE 1 5749 1 5755 15713 2025 0056 jourant L4BAE 00010 00023 047 kn Oil clearance 160 0025 0061 M LI00AE 0 0010 0 0024 LAOAE 30002 30015 m V4BAE 1 1812 1 1817 L amp OAE 35007 35018 uma OD 1 13782 13787 d L7SAE 40007 40018 Liooae 15751 15755 LAOAE 29990 30000 L BAE 1 1807 1 1811 180 34988 35000 Bearing lD 70 13775 13780 L7SAE 39988 40000 Jounal Lrooae 15743 15748 pec tee Laoac 0 002 0 025 Tight ft L48AE 00000800010 LeoaE Fitting LU 0 007 0 030 L75AE 00003 00012 L100AE I 18 Service Standards Unit mm in Parts Mode Standard Service limit Remarks 140 14989 15000 14 92 Shaft 0 ipa 5901 0 5906 0 5874 Needle bearing on 140
91. lutions and injec of the control lever tion quatity have been checked with the The access hole has an access hole pointer pump installed on the special purpose pump match mark Make sure the mark off line drive table Then a mark off line is marked matches the edge of the control lever Acces hole pointer maich mark Set ip so mat iy F O limiter ws sure o vw positon whare the governor spring is Fuel injection volume limitation adjustment 4 Adjusting the clearance on intake exhaust valve head Check the clearance at the disassembly and Locknut Adjusting screw reassembly and every 500 hours of opera tion Then adjust it if necessary Intake exhaust valve 010 015 head clearance 0 0039 0 0059 mm in cold state 1 Adjustment Adjust the clearance with a thickness Clearance 0 10 0 15 mm cold state guage 6 0039 0 0059 Adjusting the valve head clearance CAUTION Make sure each cylinder is in the T D C before adjusting the clearance This way the intake exhaust rocker arms will not move even if the crankshaft is turned clockwise or counterclockwise from the TD mark Troubleshooting 5 Troubleshooting 5 1 Troubleshooting 1 No fuel injection sound Engine allows easy manual rotation Put the regulator handle Low compression See 2 in START position pressure
92. lve 1 Observe proper handling storage and drainage procedures 2 Adjust injection pressure 5 Carbon deposits on nozzle tip 1 Clogged nozzle injection hole 1 Remove carbon 1 Proper handling of fuel using the specified fuel 6 Top clearance too large 1 Worn bearings 1 Replace the bearings 1 Proper handling of lubricating 103 Troubleshooting 5 2 Unexpected Reverse Rotation at Startup Model L A engine reverse owing to the re verse preventive camshaft Starting such an engine without sufficiently pulling the recoil may cause the engine to reverse engine is continuously run as it is the lubri Reverse rotation of engine Causes and remedies If the cating oil pump reverses accordingly thus failing to feed lubricating oil and causing the bearing metal to seize If the engine reverses immediately stop the engine using the ac celerator lever or decompression lever Main causes Special Instructions 1 Improper starting procedure 1 Slow manual turns 1 Tum faster correct assembly Proper starting procedure 2 Hard to turn manually See 5 1 3 3 Fuel injection timing too fast 1 Adjusting shims not thick enough 2 Improper alignment with gear matching mark 1 Add adjusting shims to correct injection timing 2 Reassemble Adjustment of injection timing 104 Troubleshooting
93. lve combus ion surface and check for crack and other damage Use the color penetrant to check for minute cracks p Intake and exhaust valve seats The valve seats are cold fitted in the cylinder head to improve its wear resistance Clean off carbon deposited on the valve seats since carbon build up excessive wear and corrosion can cause compression leaks Valve seats are chilled by the liquid nitrogen and inserting to the cylinder head temperature difference 190 200 374 392 F Seat width seat mm in Model 140 L100AE ltem Standard Service limit Seat angle 45 1 5 3 0 mm Seat width 0 059 0 118 in 37 Intake exhaust valve assembly 3 Intake exhaust valves and valve guides 1 Check the valve stem for wear and distor tion and replace if necessary Do not confuse the intake and exhaust valve stems 2 Check the valve sinkage Replace worn out valves See service limits below Cylinder head Sink mm Model L40AE L100AE Standard Service limit Vah 0 3 0 7 1 1 alve sinkage 0 012 0 028 0 043 InJEx Valve guide and valve stem mm n Item Valve guide I Valve stem Model Intake Exhaust Intake Exhaust 5 465 5 475 5 450 5 460 Standard 55 5515 0 2165 0 2171 02152 02156 02146 02150 Service lim
94. minus screwdriver Dust cover 4 Dust cover and shift lever 1 Separate the dust cover and shift lever 2 Remove the pinion stopper and return spring and the pinion shaft from the clutch assembly Retaining ring Pinion stopper 76 Checking and Servici Inspection Check the reduction type starter motor in the same way as the conventional type 1 Armature 1 Armature coil ground test Use a circuit tester to check for the in sulation between the commutator piece and the shaft or armature core If an insulation failure is detected replace the armature a Armature coil shortcircuit test Place the iron piece saw like one on the armature fitted to the layer short tester and turn the armature by hand If the iron piece vibrates it implies a short circuit and the arma ture should be replaced b Commutator Inspect the surface of the commuta tor If it is corroded or pitted grind with 500 600 sandpaper Replace the commutator if damage is Maintenance Wear standard limit Commutator outside diameter See separate service data Commutator run out P 83 Commutator run out Armature shaft outside diameter Measure the outside diameter of the armature shaft at four locations front center end and pinion Replace the armature if the shaft is excessively Check the bend of the shaft replace the armature if the bend exceeds
95. mp will not go out during operation Charge lamp normally works possi cues 1 Wiring is out of position or Troubleshooting is disconnected gt Check wiring Replace as required Malfunction of key switch gt Check key switch Replace if necessary Malfunction of regulator Check regulator Replace if necessary N Battery runs down sn Charge battery or replace 1 Blown fuse F Check fuse Replace if necessary 2 Refer to 1 and 2 listed above 3 Dynamo fails to generate power Caused by discon nection poor insulation or Check dynamo Repair or replace as required demagnetization 4 Malfunction of regulator gt cun SENA Check regulator Replace if necessary Attributed mainly to battery connected in reverse and abnormal temperature tise 5 Excessively low battery gt voltage Check battery Further charge battery or replace 1 Dynamo is under a load gt exceeding its capacity Reduce a load to allowable range or use dynamo with a larger capacity 2 Dynamo is frequently used in low speed range Use dynamo in high speed range often Use dynamo with a larger ity or additionally charge battery 3 Starter is hard to start and is used within a short period
96. nding section 3 2 Reduction type Option 1 Wiring Rear cover yoke and armature 4 Yoke 1 Disconnect the magnetic swich wiring 1 Extract the yoke from the armature 2 Remove the two through bolts Pull it out slowly so that it does not 3 Remove the rear cover yoke and arma strike against other parts ture Yoke armature assy Rear cover 5 Armature 1 Remove the armature from the gear case 2 Brush armature and yoke assy 1 Lift the brush spring using the brush spring lifter Touch the brush spring to the side of the brush and float the brush from the commutator 2 Remove the brush from the brush holder Brush and brush each 2 pcs 6 Pinion 1 Slide the pinion stopper to the pinion side 2 Remove the pinion stopper clip using a screwdriver 3 Remove the pinion from the armature 3 Remove the brush holder 4 Remove the armature and yoke assem bly 75 Checking and Servicing 5 Clutch assembly with pinion shaft 1 Remove the gear case housing mounting screws 2 Remove the clutch assembly w pinion shaft from the gear case 3 Magnetic switch 1 Remove the magnetic switch mounting bolts 2 Remove the magnetic switch 3 Separate the torsion spring from the magnetic switch Magnet switch 2 6 Clutch disassembly y 1 Move the pinion stopper toward the pin e ion and remove the pinion stopper clip with a
97. ng must be accomplished in three stages rough medium and finishing tap These taps must be applied in this order and centered correctly to avoid the mis alignment of threads When the hole is tapped successfully throughly blow clean the hole with compressed air before in serting the helical insert part Tapping 3 Insertion Apply the helical insert to the hole with the inserting tool while the tongue is looking downward Holding down the insert turn the handle clockwise Then the insert is screwed into the hole 4 Removing the tongue To remove the tongue hit the head of the tongue removing tool with a hammer Removing the tongue 5 Removing the helical insert It is not necessary to remove the helical insert unless especially required The helical insert can be removed by turning it counterclockwise 4 Where herical insert part can not be used The helical insert part may be used for all parts except on the unevenly worn screw of the valve rocker arm support lock bolt on the cylinder head Helical inserting Part for Repair 116 Difference between Parts under Spec S and D Appendix 1 Spec S and D Difference Between Parts under Direction of rotation viewed from PTO side PTO shaft PTO Crankshaft _ 5 Camshaft Clockwise D Crankshaft Counterclockwise Model L60AE S S spec Model L60AE D D spec Us
98. ormally 1 Disconnect the generator output from the regulator with the generator left coupled with the engine 2 Connect the generator output to a volt ammeter 3 Set the volt ammeter to the 100 VAC range 4 Start the engine and check the volt amme ter 5 When the volvammeter reads the specified value the generator is in normal operation Measure voltage between the connectors Voltage VAC GP 9585 GP9589 GPose7 GPesos M he voltage is too low 3750rpm Approx 357 53 8 Approx 454 aoas Gemagnetredor 3200 mpm Approx 303 Approx 46 Approx Approx 355 disconnected Stator coil continuity test Disconnect the green white wire to the dynamo or red and black connectors Check the stator Coil for continuity using a circuit tester If continuity is not detected Q replace the stator coil which is disconnected Note When the megger is used short the circuit within 1 or less second Coil insulation test Remove the green and white or red and black conductors from the dynamo 1 Connect a cable from the megger or cir Cuit tester to the G W wire or red con nector 2 Connect the other cable from the megger or circuit tester to the cylinder block for 1 or less second and check the indicator of the megger or circuit tester If there is continuity the registance is zero replace the stator coil Tester s reading Continuity Evalua
99. over runs the starter motor has an over running clutch Over running clutch 72 Checking and Servicing 2 Operation Key switch ON Serie s coil are energized Shunt Shunt 4 Series contactor coi Torsion spring Plunger is attracted Pinion and reid PA pinion shaft are pushed out by shift Pinion Pinion is normally Pinion ring gear i 1 Pinion is engaged with ring gear Pinion is engaged with Pinion is not engaged ring gear with ring gear Torsion spring and plunger moves again Main contactor closes to Main contactor closes to carry a large current to a large current to moter Rotated armature tums Rotated armature pinion through reduction pinion through reduction gears gears Ting gear is rotated Pinion is released from ing gear and enegaged with ring gear by torsion Check if engine has started Turn key switch OFF Magnetic switch no longer attracts pinion Main contactor opens mme __ Plunger and shift lever are returned to the original position by torsion spring pinion by pinion return spring Motor armature stops Key switch is turned off 73 Checking and Servicit surrou
100. owable limit mm in L4QAE L100AE Parallelity or distortion 0 05 0 0020 2 Side gap of connecting rod Re attach the connecting rod to the crank pin to make sure the gap in the crankshaft direction is proper Make sure the thrust surfaces on both ends are not damaged mm in Model L40AE L100AE Side gap 0 2 0 4 0 0079 0 0157 Small amp large end hole of Connecting Model LAOAE 148 LGOAE L70AE L75AE L100AE Service Service Standard limit Standard mit Standard imit 19012 19024 19 10 21014 21028 2110 23025 23038 2310 Smat end 0 7485 0 7490 0 7520 08273 08279 0 8307 09065 09070 0 9094 Piston pin 7 0 016 0 030 7 0 017 0 034 a 0 026 0 044 Z clearance 0 0006 0 0012 0 0007 0 0013 0 0011 0 0017 ID 30007 30015 30 09 36007 36015 3609 40000 40042 4008 Lageend direction 11814 13817 1 1846 1 4176 1 4179 1 4209 1 5748 1 5765 1 5780 Crank pin OW 0 025 0 050 0 025 0 050 0033 0062 clearance 0 0010 0 0020 0 0010 0 0020 00013 00024 Material L40AE L7OAE Aluminum alloy stamp forging L75AE L100AE Carbon steel alloy stamp forging 2 Checking the crank pin metals 1 Check the contact surface of the crank pin metals for separation melting seizure etc Replace it if it is separated or damaged
101. per part of the piston 2 Reassemble the gasket packing and the head Tighten them to the specified torque in the specified tightening order 3 Press down the fuses with the piston by turning the crankshaft in its normal direc tion 4 Remove the cylinder head and take out collapsed fuses Measure the thickness of three crushed fuses Instead of removing the cylinder head thread a string tied to the fuse through the nozzle hole pull it out to bring the fuse on the cylinder head as shown in the figure below and apply step 3 described above 5 The top clearance is the average of the three measured thicknesses Obtain the mean value of the three thicknesses mm Item Standard LAOAE L48AE 160 L70AE L75AE L100AE Service limit Standard Standard Service limit Free length A 265 28 1 102 1 043 315 1 240 40 39 5 1575 1555 Inclination B 075 0 030 Service limit lt 10 0 039 Spring tension perimm kg Ib 2 51 3 09 114 14 127 155 2 80 3 42 1 80 2 51 8 97 5 51 39 mm n L40AE L100AE Standard Top clearance 90167 01276 9 r et icing 6 Intake and exhaust valve rocker arms and push rods 1 Valve rocker arm shafts Measure the O D of the shaft and the 1 0 of
102. roper fuel oil exhaust smoke Irregular imperfect Poor fuel injection performance rotation combustion fluctuation Improper fuel injection timing Good Combustion Some malfunction of moving parts Causes and remedies Main causes Remedies Special Instructions Malfunction related to governor 1 Poor performance related to governor lever a Improper governor adjustment b Improper sliding of governor lever shaft Governor lever interference 2 Faults in the governor a Loose bolt b Poor weight action Too much play in spring fitting 3 Regulator spring incorrectly positioned 1 Adjust or replace a Adjust governor b Lubricate or repair Repair or replace 2 Adjustment Increase the tightening torque b Repair Adjust play of spring 8 Adjust the mounting position 1 Adjusting method How to adjust governor Low quality or contaminated fuel o Changed to specified fuel Procedure for selecting and handling fuel oil Poor fuel injection performance 1 Nozzle sticking 2 Worn damaged nozzle valve seat 3 Low injection pressure 1 File or replace the nozzle 2 Same as 1 3 Adjust injection pressure Methods of handling fuel oil Too fast too slow fuel injection timing Adjust injection timing using adjusting shim Adjusting fuel injection timing Malfunction of moving parts 4 Camshaft side gap too large
103. s motor is equipped with reduction gears between the armature and pinion the re duction gears increase the torque of the motor before transmitting the torque to the pinion The pinion and pinion shaft are shifted by the magnetic switch but the clutch assembly remains unmoved 1 Circumscribed type The armature shaft is equipped with a small gear at the end which is constantly engaged with a large gear on the circum ference of the clutch Thus the revolu tion of the armature is transmitted to the pinion through the reduction gears and the clutch assembly While the engine is being cranked the motor emits a slightly loud sound because of the built in reduction gears This does not mean of course a sign of trouble Torsion spring Torsion spring 2 Internal structure of reduction type Illustration above shows the internal structure of the reduction type starting motor This motor is similar to the mag netic shift type motor except that it has a built in reduction mechanism as its name implies general type of staring motor the ar mature is designed to turn at the same Tpm as the pinion However the reduc Checking and Servicing tion type motor has its internal resistance reduced to about 25 33 of the coventional motor to a high speed low torque motor while being a high torque motor by use of reduction gears To prevent the motor from being affected by a shock when the engine starts and
104. starter using a screwdriver as shown in Fig Then wind back the rope until the reel stops to turn by turning the reef with your thumb at the reel s notch LAOAE 148 Retum spring Friction spring b L60AE L70AE Disassembly and Reaseembly 3 Remove the parts as shown in Fig b d To remove the E ring fasten the shaft by the pliers and twist the E ring left and right Model L60AE L70AE have an additional slide plate Model L40AE L48AE and L75AE to 1100 have only the friction plate Model L6OAE to 100AE differ in the recoil starter complete and tightening nut both of which are used for the threaded recoil shaft 175 1 100 Lock nut Spring washer Washer Washer B D _ Friction plate Disassembly and Reaseembly 4 Remove the reel from the starter case as shown in Fig e Take out the reel slowly while turning it lightly to the left and right to remove the spring Take care not to take out the reel quickly Otherwise the spring may jump out its housing If the spring runs out of position put it in the starter case as illustrated in Fig 0 2 Wind the starter rope around the reel to the arrow mark direction as shown in Fig g Take out the rope from reel s notch at the 2 5 tums fit the reel s hook to the inner end of the spring and reassemble the reel cor rectly into the starter case The reels hook can t be seen on reassembly
105. t 1 Stem color check Clean the crankshaft and check for flaws using the color penetrant or by magnaflux inspector Ball bearing Replace the crankshaft if it is cracked or badly damaged 2 Measuring the crank pin and journal Check the crank pin and journal for surface wear If the and journal be ris Crankshaft yond the allowable limit replace the it uate crankshaft assembly or grind them and fit them with an undersized bearing metal Crankshaft mm n Model TAOAE ASAE TSOAE L7OAE 7 Sonico ltem Standard damit Standard mit Standard limit Pin 29985 20982 2990 35965 35982 3590 30965 39982 9990 OD 14797 11804 1 1772 14159 14166 1 4134 15734 15741 1 5709 20250055 0025 0055 3933 0082 Clearance 0 0010 0 0022 2 0 0010 0 0022 0 0013 0 0024 Journal 90008 00015 200 35002 95010 sas 40002 40018 39091 OD ddeactietn 11776 13780 13787 13744 15749 15755 1 8719 0 025 0 058 0 17 0 025 0 061 0147 0 025 0 061 047 00010 00029 0 0067 00010 00024 00067 00010 00024 00067 joumal Journal 30 002 90 015 35007 35018 40007 40016 1 1812 1 1817 1 3782 1 3787 1 5751 1 6755 Fiywheel Bearing 20290 30000 34999 95000 29989 40000 side 1 1807 1 1811 1 3775 1 3780 E 1 5743 1
106. the measured value exceeds 0 2kg Spring balance T Limit Standard value 2 Sting Brush spring km Measuring brush spring force Standard spring load 20kg CAUTION Whenever overhauling the motor or removing the brush apply high quality grease to the specified greasing point This extends the service life of the bearing on the brush side although the bearing uses an oilless alloy 4 Brush holder ground test Check the continuity between the insu lated brush holder and the base grounding of the brush holder as sembly Continuity indicates that these two points are grounded and that the holder must be replaced Checking and Servicir 5 Adjustment and Performance test 1 7 measurement gap between pin ion and pinion stopper Conventional starter motor When the pinion is at the projected posi measure the gap between pinion and pinion stopper This measurement should be made with the pinion pressed back lightly to take up any play in engagement linkage mm 4 dimension 0 3 2 5 0 012 0 098 Measuring of dimension Reduction type Connect the wiring as shown in the sketch below on the switch and measure the dis tance in the pinion thrust direction mm in 4 dimension 0 3 1 5 0 012 0 059 Measuring of dimension 81 2 Pinion movement To measure the dimension connect th
107. the continuity between the termi Tal and M of the magnetic switch ts 1 inspect the pinion teeth and replace the detected pinion if the teeth is excessively worn or damaged 2 Check if the pinion slides smoothly re place the pinion if faulty 3 Inspect the springs and replace if faulty 4 Replace the clutch if it slips or seizes 5 Brush The brushes are quickly worn down by the motor When the brushes are deflective the output of the motor will drop Coil resistance at 20 C 0 330 3 Contact test of contactor Push the plunger with your finger and check the continuity between the M ter minal and B terminal If discontinuity the 1 Brush dimensions Replace brushes which have been worn beyond the specified wear limit 14mm 0 557 Wear imit 11 mm 0 437 Reduction USED f type 16 mm 0 63 2 Brush appearance and movement in brush holder If the outside of the brush is damaged replace it If the movement of the brushes in the brush holder is hampered because the holder is rusted repair or replace the holder 3 Brush spring Since the brush spring pushes the brush against the commutator while the motor is running a weak or delective spring will cause excessive brush wear resulting in sparking between the brush and the commutator during operation Measure the spring force with a spring balance replace the spring when the difference between the standard value and
108. the valve rocker arm Replace the valve rocker arm shaft or valve rocker arms if it exceeds the service limits INJEX Valve rocker arm mm in Model L40AE L70AE L75AE L100AE ltem Standard Service limit Standard Service limit O D of IN amp EX vaerocker arm 0 4720 0 4724 0 4688 0 S901 05909 0 5866 LD of IN amp 12 016 12 034 12 10 15 016 15 034 15 10 valve rocker arms 0 4731 0 4738 0 4764 0 5912 0 5919 0 5945 2 Push rods Check the push rod length and distortion Push rod mm n item Push rod length Push rod distortion Model Standard Service limit Standard Service limit L40AE L48AE 129 8 130 2 5 110 5 126 L60AE L70AE 1623 1627 6 390 6 406 lt 0 05 0 0020 0 3 0 0118 L75AE L100AE 196 8 197 2 7 748 7 764 40 Checking and Servicing 7 Adjusting the valve clearance 1 The valve clearance should be adjusted while the engine is in the cold state Adjusting screw Valve clearance mm n Modell LAOAE L100AE hem Standard Intake 0 15 Exhaust 0 0 059 2 The table below shows the proper valve 4 2 PISTON AND PISTON PIN 1 Piston CAUTION The intake exhaust valve recesses are added to the top surface of the piston applicable to L40AE L70AE as a result of a change in the camshaft When replacing piston take special care of interchangeability of par
109. tion NO Normal YES Abnormal Replace the stator Checking and Servicing Inspection of dynamo regulator combination To inspect the dynamo regulator connect a voltmeter and ammeter to the dynamo regu lator circuit as illustrated below Use a battery capable of running the engine GP9595 Voltmeter w Regulator RS5112 6 Annot i taney sl sw Y Charge lamp Relationship between charge current and battery terminal voltage at 3600rpm Evaluation Cause 14V or less 2A or more GP9587 Norm E 13 5 A or more GP9595 x 14 15V 2 02A GP9587 within range of voltages Normal regulated by the regulator 13 5 GP9595 i 15V or more 2A or more GP9587 13 58 or more apace Abnormal Replace the regulator which is faulty 15V or less charge current 0A The regulator or dynamo is faulty or wires are improperly connected A charge current flows but the battery fails to attain a desired terminal voltage The battery is dis charged Replace the battery which is faulty 86 Checking and Servicing Inspection of discrete regulator simplified inspection Check the continuity between the terminals on a discrete regulator listed the table below The continuity between the regulator case and each terminal must also be checked The v
110. tion and cause of such failures 100 Troubleshooting Symptom Condition Cause Damage due to 1 Engine generates abnormal 1 Motor is internally bumt 1 Key switch fails to return overrun sound during operation 2 Commutator breaks and smooth caused by a bent 2 Starter fails to start smooth scatters key or dust deposited on 3 Wire hamess is fused 3 Pron ctch is discolored key creumterence caused short circuited Grease scatters 2 Intermediate relay has wiring in starter 4 Magnetic switch coil is contact fused 4 Key switch is tumed OFF bumt Odors occur and Key switch is repeatedly but engine is still cranked plunger sticks operated because of misfire of engine Fused contact of 1 Reterto1 to listed above 1 Relerto 2and4lsted 1 Banery is discharged magnetic switch 2 Key switch is tumed OFF above Note that pinion because of sparks that but starter will not stop clutch is free from trouble result from repeated ON Engine is not cranked OFF operation of magnetic Z 2 Wire harness stacks off 3 High impedance at SWitchings circuit 4 Small pinion gap that may cause spark when the Contact closure is opened 12 by such as vibration 101 5 Insufficiently charged battery Charge lamp will not light when key Switch is turned to ON during a stop lamp Check whether is burnt Charge la
111. ts 1 Checking the piston top and combustion surface Remove carbon build up on the piston top and combustion surface Be careful not to scratch the surface Check the combustion surface for damage 2 Checking and measureing piston O D 1 Replace the piston if the outer surface and ring groove are damaged exces sively 2 Measure piston O D across the piston pin approx 12 mm 0 47 in from the bottom end of the piston timing Valve timing Model 40AE L70AE L75AE L100AE Item Standard Intake Pen bTDC25 bTDC 20 dosed aBDC 59 aBDC 53 59 bBDC 53 Exhaust Giosed _ 25 aTDC 20 8 Identification of cylinder head Model L70AE is provided with the cylinder head peculiar to the model and has an iden tification stamp accordingly identification stamp 170 7 41 3 Piston and piston pin To remove piston pin heat piston to 70 80 C 158 176 F before extruding it To reassemble it repeat the same step 2 Piston pin Measure the O D of the piston pin Replace if it worn exceeds the service limit or exces sively stepped and worn Measuring point of piston pin Piston pin O D mm in Model LA0AE 148 L60AE L70AE L75AE L100AE 18 992 19 000 20 991 21 000 22 991 23 000 0 7477 0 7480 0 8264 0 8268 09052 09055 tenn 18 92 20 91 22 91 Service Limit 0 7
112. uipment required for service 1 Tools 2 Meters and instruments 8 Others Service Information 1 GENERAL SAFETY STOP THE ENGINE BEFORE SERVICING 1 2 3 4 5 PREVENTING FIRES 4 Never add fuel to the fuel tank while the engine is running Wipe away all fuel spills with clean cloth Keep gasoline kerosene matches other explosives and inflammables away from the engine since the temperature around the exhaust silencer is very high during operation 4 To prevent fire hazards and to provide adequate ventilation keep the engine at least 3 ft 1m away from the building and other equipment during operation PREVENTING EXHAUST GAS INHALATION Note that exhaust gas contains carbon monoxide CO nitrogen oxide NOx hydrocarbon HC sulfar oxide SOx and particulates Never use the engine in poorly ventilated locations such as indoors inside of tunnels and so on f indoor operation is unavoidable provide proper ventilation so that people and cattle will not be affected PREVENTING BURNS Never touch the exhaust silencer muffler cover or engine body while the engine is running or hot PRECAUTIONS FOR THE BATTERY The battery electrode is essentially dilute sulfuric acid which injures the human body and damages clothes Should it touch the body or clothes immediately wash it away If it enters your eye hasten to consult the doctor Never use fire near the battery during chargin
113. volution Counterclockwise viewed from PTO shaft Fuel injection pump Bosch type YANMAR PFE M type Fuel injection timing FID bTDC 13 Fuel injection nozzle Hole nozzle YANMAR YDLLA P type Fuel oil Fuel injection pressure 19 6 200 Fuel oil selection Diesel fuel BS 2869 A1 or equivalent Fuel oi fiter Paper element FO tank built in type Fuel oil tank capacity 05 gal 5 5 1 45 Lubricating fiter Resin 60 mesh Lubicating oil Lubricating oil selection SAE 10W30 API grade or higher Lubricating oil capacity US gal 505 Air cleaner Wet type paper element filter Oil bath type Option Exhaust silencer Expansion silencer with cover Governor All speed type mechanical Engine dimensions Length x Wath x Height mm in S SPO 392 x 470 x 494 15 495 x 18503 19449 Dry weight kg b 485 106 9 54 0 119 0 48 5 106 9 5 amp 0 119 0 Permissible angle of inclination deg 20 momentary 30 Balancer shaft Single shaft Specifications shens Model L100AE Hem D T 5 DE SE Type Single ylinder vertical 4 cycle air cooled diesel Cooling system Forced air cooling by flywheel fan Combustion system Direct injection system Starting system Recoil starter 4 Number of cylinders Bore x Stroke mm in 9 386

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